Ford - Expedition 4wd - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-5.4L (2007) 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 (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 10 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair ANTENNA ISOLATOR MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the antenna cable connector, the antenna isolator module electrical connector, and the antenna isolator module-to-quarter glass connector. 3. Remove the stud and the antenna isolator module. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 17 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 18 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 19 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module sub-harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking aid module bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Remote Control Module, Audio - Stereo > Component Information > Locations View 151-19 (Center Console - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Remote Control Module, Audio - Stereo > Component Information > Locations > Page 23 C3077 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 28 Memory Positioning Module: Diagrams C341A C341B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 29 C341C C341D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 30 C341E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation DRIVER SEAT MODULE - MEMORY SEAT The power driver seat, power outside rear view mirrors, power adjustable pedals and adjustable steering column are controlled by the driver seat module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM is located on the driver seat track. This system allows automatic positioning of the driver seat to 2 programmable positions. The memory seat system consists of the following components: - DSM - Driver memory seat control switch - Memory set switch - Adjustable pedal switch - Power mirror switch - Adjustable steering column switch - Memory seat track assembly (with seat position sensors integral to motors) Horizontal motor (part of seat track) - Front height motor (part of seat track) - Rear height motor (part of seat track) - Backrest power recliner motor (with integral position sensor) (part of backrest frame) - LH memory power mirror - RH memory power mirror - Power adjustable memory pedals - Power adjustable steering column - Remote keyless entry transmitter Two personalized seat positions may be programmed into the memory seat system. A memory seat position may be set by first positioning the driver seat using the driver power seat switch and depressing the memory set switch. Memory seat position 1 or 2 must be selected within 5 seconds to set a personalized seat position. If position 1 or 2 is not selected within 5 seconds, the operation is aborted. This operation also aborts if any input is received from the driver power seat switch, the power mirror switch, the adjustable pedal switch, the power adjustable steering column switch or if the memory set switch is depressed again during the 5-second limit. The personalized memory seat positions are recalled using the memory switch positions 1 and 2 or with the remote keyless entry transmitter. A programmed seat position can only be recalled when the transmission selector is in PARK or NEUTRAL with the ignition switch in the RUN position. A position may be programmed at any time. For information on the DSM, refer to Body Control Systems (Multifunction Electronic Control Module). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 38 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 41 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 43 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 44 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 45 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 54 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 60 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 61 Power Trunk / Liftgate Control Module: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 62 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 63 Power Trunk / Liftgate Control Module: Diagrams C4174A C4174B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 64 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the bolt. To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 2 bolts and the retractable running board module assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: Customer Interest A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 76 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: All Technical Service Bulletins A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 82 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 83 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 84 Seat Heater Control Module: Diagrams C3265A C3265B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 85 C3265C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 86 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When installing a new climate control seat module (CCSM), carry out the appropriate steps in the programmable module installation (PMI) procedure. 2. Position the front passenger seat fully upward and depower the supplemental restraint system (SRS). 3. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 4. Release the 2 tabs and slide out the CCSM. 5. Remove the CCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. If a new CCSM has been installed, carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-43 (Roof - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 90 View 151-45 (Roof - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 91 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 96 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 97 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 100 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 102 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 104 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 105 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 106 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 117 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 118 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 124 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 125 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 126 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 127 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 128 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module 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 air cleaner outlet pipe from the air cleaner cover. ^ to install, tighten the clamps to 4 Nm (35 inch lbs.) 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the 3 hydraulic control unit (HCU) bracket bolts. ^ To install, tighten to 20 Nm (15 ft. lbs.) 6. Disconnect the anti-lock brake system (ABS) module electrical connector. 7. Remove the 4 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.) 8. To install, reverse the removal procedure. ^ If installing a new ABS module, program the module. For additional information, refer to Information Bus (Module Configuration). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 132 C2142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 138 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 140 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 143 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 144 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 145 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 146 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 147 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 148 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 150 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 151 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 152 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 153 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 157 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 is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 158 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 159 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 160 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module > Page 165 View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module C228A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 168 C228B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 169 Control Module HVAC: Diagrams Manual Climate Control Module C2357A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 170 C2357B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 171 C2357C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 176 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 177 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 178 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 183 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 186 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 187 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 188 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 190 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 195 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 198 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 199 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 200 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 201 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 207 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 208 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 211 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 212 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 213 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 214 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 215 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 216 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 217 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 218 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 223 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 224 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 228 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 229 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair SMART JUNCTION BOX (SJB) Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new SJB after installation. 1. NOTE: - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - A new SJB is delivered in "manufacturing mode" with 7 pre-set DTCs. These 7 manufacturing mode DTCs require that a successful configuration of the SJB occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. All of this is required in order to clear the 7 manufacturing mode DTCs. The 7 manufacturing mode DTCs are as follows: B2477 (Module Configuration Failure) - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-state) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the pin-type retainer and the RH A-pillar lower trim panel. 4. Remove the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 233 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. - Tighten the screws to 2 Nm (18 lb-in). 2. Connect the 7 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 the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicate the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. Carry out the SJB on-demand self-test by clearing DTCs and then retrieving DTCs to confirm all DTCs have been cleared. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 238 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 239 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 242 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 243 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 244 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 245 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 247 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 248 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 249 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 254 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 255 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 256 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 257 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 258 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 259 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 260 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 261 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 262 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 263 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 266 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 267 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 268 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 269 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 270 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 273 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 274 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 275 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 276 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 277 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 279 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 280 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 281 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 282 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Programmable Module Installation Body Control Module: Service and Repair Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the Original Module is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation Using the Integrated Diagnostic System IDS) When the Original Module is NOT Available NOTE: Following module installation, some modules require a separate learning procedure carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press check mark. 8. If the data is not available, the IDS displays screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Programmable Module Installation > Page 290 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. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (TP) sensor, 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 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 (2007)) 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 294 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 convened 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 (2007)) 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 295 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 (2007)) 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 296 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. 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 (2007)) 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 297 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 (2007)) 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 298 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 4% - Out of range, limp home default position. - Greater than or equal to 4% 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 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 307 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 312 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 318 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 323 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 324 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 327 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 328 orientation. 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 (2007)) 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 329 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 330 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 331 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 332 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 333 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 334 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 335 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 336 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 337 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 338 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 339 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 340 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 341 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 342 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 343 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 344 Engine Control Module: Connector Views C175B (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 345 C175B (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 346 C175E (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 347 C175E (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the battery ground cable. 3. Disconnect the 2 PCM electrical connectors. 4. Remove the 2 bolts and the ground cable. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the PCM. 6. To install, reverse the removal procedure. Installation 1. Install the PCM. 2. Position the ground cable and install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Connect the battery ground cable. 5. NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON. The warning indicator will remain on until PCM configuration is restored - Clear all restraints control module (RCM) continuous diagnostic trouble codes (DTCs) after Programmable Module Installation procedure has Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) > Page 350 been completed on the PCM. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) > Page 351 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. 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 needs 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 using a scan 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. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 355 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 356 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 357 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 362 Fuel Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 363 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 364 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 368 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 369 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 370 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 375 Ignition Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 376 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 377 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 382 Air Bag Control Module: Diagrams C310A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 383 C310B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 384 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, a new RCM must be installed whether or not the air bags have deployed.In addition, make sure the area of the RCM mounting is restored to its original condition.Failure to follow these instructions may increase the risk of personal injury or death in a crash. CAUTION: Prior to removal of the RCM module, it is necessary to upload module configuration information to the scan tool.This information needs to be downloaded into the new RCM module once installed.Refer to Information Bus (Module Communications Network). NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON.The warning indicator will remain on until PCM configuration is restored.Clear RCM DTCs. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed.RCMs are not interchangeable between vehicles or vehicle lines.If an incorrect RCM is installed, erroneous DTCs and incorrect diagnosis 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 warning indicator if a fault is detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). 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 request illumination of the air bag warning indicator located in the instrument cluster. When the ignition switch is cycled (turned OFF and then ON), the air bag warning indicator will prove out by lighting for 6 seconds and then turn off.If a SRS fault exists, the air bag warning indicator will illuminate and remain illuminated for the rest of the key cycle.The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool.If the RCM requests illumination of the air bag warning indicator and the air bag warning indicator does not function, the instrument cluster module will automatically 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 warning indicator require repair. The RCM includes a backup power supply.This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is lost or damaged during impact.The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. A new RCM installed in a vehicle will flash lamp fault code (LFC) 54 until programmable module installation (PMI) has been carried out on the RCM.If a LFC is present after completing PMI, a fault is present in the SRS and on-demand DTCs must be retrieved and diagnosed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 385 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 RCM orientation is critical for proper air bag SRS operation. If a vehicle equipped with an SRS system has been involved in a Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 386 collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed 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. - When installing a new RCM, it is necessary to carry out programmable module installation (PMI). NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new 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 1. If installing a new restraints control module (RCM), carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the system. Vehicles with a center console 3. Remove the center console. Vehicles with bucket seats and no center console 4. Remove the 3 RCM push-nut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 387 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Install the RCM and 3 bolts. Tighten to 11 Nm (8 lb-ft). 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 388 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats and no center console 6. Install the 3 RCM push-nut retainers and the RCM cover. Vehicles with a center console 7. Install the center console. All vehicles 8. Repower the SRS. Do not prove out the SRS at this time. 9. When installing a new RCM, carry out the steps necessary to complete programmable module installation (PMI). 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash. The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 389 exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous memory diagnostic trouble codes (DTCs) from the RCM. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 395 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 398 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 399 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 400 Starter Relay: Testing and Inspection Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 401 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 402 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 408 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 409 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 410 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 414 Suspension Control Module: Diagrams C2131A C2131B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 415 Suspension Control Module: Service and Repair Air Suspension 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. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 lb-in). 4. 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 LH and RH ride height sensors are calibrated and a pneumatic test is carried out. For additional information, refer to Vehicle Dynamic Suspension Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 426 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 431 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 436 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 437 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 438 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 444 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 449 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 454 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 455 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 456 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 461 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 462 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 467 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 468 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 469 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 474 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 477 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 478 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 479 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 480 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 481 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 495 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 501 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Speedometer Head: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 507 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 513 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 514 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 515 C2089 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 516 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 517 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 518 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 534 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 540 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 541 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 542 C2089 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 543 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 544 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 545 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 550 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 553 C605 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 554 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 555 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 556 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 560 C527 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 561 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 562 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 563 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 564 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 569 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 570 Power Seat Motor Position Sensor: Locations Height Sensor, Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 571 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 574 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 575 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 576 C4092 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 577 C4093 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 582 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 583 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left/Right View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 584 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 587 Power Seat Switch: Diagrams Power Seat Switch, Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 588 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 589 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 592 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 593 Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 594 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 595 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 596 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 597 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 598 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 599 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 600 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 601 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 603 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 604 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 605 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 606 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 607 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 608 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 609 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 610 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 611 Power Seat Switch: Service and Repair MEMORY SET SWITCH Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 612 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 613 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 614 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 615 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. 1. Depower the supplemental restraint system (SRS). 2. Detach and position aside the driver seat cushion side shield cover. 3. Release the clips and remove the memory set switch. - Disconnect the seat control switch. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair Power Trunk / Liftgate Hazard Sensor: Service and Repair PINCH STRIP SWITCH Removal and Installation NOTE: Left side shown, right side similar. 1. Remove brake light. - Remove the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Page 619 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1 Remove the pin-type retainers. 2 Remove the grommet and route the harness out of the vehicle. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-41 (Liftgate - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch C4340 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 625 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front Seat Heater Switch: Service and Repair Seat Control Switch - Front SEAT CONTROL SWITCH - FRONT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 633 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 634 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 635 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 636 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. All seats 1. Position the seat forward and upward to aid in seat control switch removal. 2. Depower the supplemental restraint system (SRS). 3. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. Power seat with manual recliner 4. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 637 5. Remove the cushion side shield cover forward screw. 6. CAUTION: Do not damage the manual recliner lever when removing the cushion side shield cover. Remove the cushion side shield cover. Partially remove the cover to gain access to the seat control switch. - Release the retainers and detach the seat control switch from the side shield cover. - Remove the cushion side shield cover. All seats 7. Detach and remove the cushion side shield cover. - Disconnect the seat control switch. - If equipped, disconnect the memory set switch electrical connector. 8. Release the clips and remove the seat control switch. 9. To install, reverse the removal procedure. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 638 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. Reach a hand behind the RH rear quarter trim panel and squeeze together the 2 tabs on the affected seat control switch to release. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 642 C3246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 647 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 648 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch C4333 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 651 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 656 View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 657 C3073 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 658 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 659 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 663 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 667 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 671 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 675 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: Customer Interest ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 684 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 689 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 690 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 696 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 701 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 702 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 703 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 3 Nm (27 inch lbs.) 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 707 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 708 Traction Control Switch: Service and Repair Stability/Traction Control Switch - Expedition Stability/Traction Control Switch - Expedition Removal and Installation 1. Remove the lower instrument cluster center finish panel. 2. Remove the upper instrument cluster center finish panel. ^ Disconnect the electrical connectors. 3. Depress the 4 tabs and remove the traction control switch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 709 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 718 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 719 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 724 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 730 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 731 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 736 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 739 Wheel Speed Sensor: Locations Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 740 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 743 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 744 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 745 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) 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 748 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 757 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 758 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 764 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 765 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 766 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 767 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 776 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 777 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 778 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 783 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 786 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 (DTC) is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 793 Navigator Removal and Installation Expedition NOTE: It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 798 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 799 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the engine oil pressure (EOP) switch electrical connector. ^ To install, tighten to 18 Nm (13 ft. lbs.) 3. Remove the EOP switch. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 807 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 808 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector positions except OFF. The blower motor switch is mounted to the climate control assembly and can be separately installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 812 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 818 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor 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 3 lower steering column cover screws and the lower steering column cover. - Disconnect the electrical connector. 2. Remove the 4 steering column reinforcement bolts and position the steering column reinforcement aside. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the in-vehicle temperature and humidity sensor. 1 Detach the in-vehicle temperature and humidity sensor from the instrument panel finish panel. 2 Disconnect the aspirator hose. 3 Disconnect the in-vehicle temperature and humidity sensor electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 821 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 825 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 826 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Discharge Air Temperature Sensor EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR The evaporator discharge air temperature sensor communicates the evaporator discharge air temperature to the electronic manual temperature control (EMTC) module (if equipped) or electronic automatic temperature control (EATC) module (if equipped). The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing in the air-stream leaving the evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor > Page 829 Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Evaporator Temperature (ACET) Sensor 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 changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 830 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Diagrams C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 837 C1260 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer A/C PRESSURE TRANSDUCER The A/C pressure transducer communicates the compressor discharge pressure to the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates excessively high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 840 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch AIR CONDITIONING (A/C) CYCLING SWITCH The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 841 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 842 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor AIR CONDITIONING PRESSURE (ACP) TRANSDUCER SENSOR A/C Pressure Transducer Sensor Output Voltage Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 846 Solar Sensor: Diagrams C286 C2360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 852 Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 853 Vehicles with power tilt 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 858 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 859 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 860 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 863 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 864 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 865 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 874 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 879 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 885 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 890 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 891 Fuel Gauge Sender: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 892 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 893 C433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 894 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 895 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 896 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 897 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 901 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Removal and Installation 1. Using a suitable tool, remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 909 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 910 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 911 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation CAUTION: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 919 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 920 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 921 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 924 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 925 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 926 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 930 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 936 C2065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 939 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 940 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 941 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 945 C205 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 946 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 947 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 948 Headlamp Switch: Service and Repair HEADLAMP SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 949 Navigator Removal and Installation Expedition 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-17 (Steering Wheel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 953 C217 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 957 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 958 Turn Signal Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 959 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 960 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 961 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 967 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 968 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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 972 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 973 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 (2007)) 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 974 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 975 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 984 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 990 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 991 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 994 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 995 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) 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 996 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1003 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1004 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1005 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1009 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1010 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1011 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 (2007)) 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) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1015 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1016 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1020 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1021 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1022 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1023 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR 106L (28 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1024 106L (28 Gallon) Fuel Tank (Part 2) 125L (33 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1025 125L (33 Gallon) Fuel Tank (Part 2) Removal and Installation All fuel tanks 1. Remove the fuel tank. 106 L (28 gal.) fuel tank 2. Disconnect the supply and return fuel tubes quick connect couplings from the fuel filter. All fuel tanks 3. Remove the fuel tank heat shield retainer(s) and remove the fuel tank heat shield. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 5. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 6. NOTE: For the 106 L (28 gal.) fuel tank the fuel tank pressure sensor and vapor tube assembly and fresh air tube are serviced as an assembly. Remove the fuel tank pressure sensor and vapor tube assembly with the fresh air tube from the fuel tank. 125 L (33 gal.) fuel tank 7. Remove the fuel tank pressure sensor and vapor tube assembly from the fuel tank. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1026 - Leak test the system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1030 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1031 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 fuel, spark, and air flow. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1032 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. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1038 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1039 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1040 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 1051 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 1052 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 1053 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 1054 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 1055 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1058 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1059 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1060 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1061 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 (2007)) 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 (2007)) 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 1064 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1065 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 (2007)) 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 1066 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. 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. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1071 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 1075 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1079 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1082 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1083 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1088 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1089 orientation. 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 (2007)) 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 1090 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1091 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1092 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1093 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1094 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1095 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1096 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1097 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1098 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1099 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1100 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1101 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1102 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1104 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 that is generated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1109 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 1114 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1119 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1120 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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1124 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1125 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 (2007)) 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 1126 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1127 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1132 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1139 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1140 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1141 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 (2007)) 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 1142 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 (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1146 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1149 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1150 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 1160 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 1166 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1167 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1170 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1171 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1172 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1176 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1177 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1178 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1184 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1190 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1191 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1192 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1198 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1199 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1200 Impact Sensor: Locations Safety Canopy Sensor, Driver 2 View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1201 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1202 Impact Sensor: Locations Safety Canopy Sensor, Passenger 2 View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1203 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1206 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1207 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1208 C3314 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1209 C3315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1210 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, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - 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. Install a new and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. For these vehicles, the SRS uses 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel, the second row sensors are located on each C-pillar. The side impact sensors are not interchangeable between the first and second row. Mounting orientation is critical for correct operation of all impact sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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. - The front impact severity sensor is located on the bottom of the lower radiator support. 1. Depower the system. 2. Disconnect the front impact severity sensor electrical connector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1213 - Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of the locator tab on the front impact severity sensor for installation. Remove the bolt and front impact severity sensor. To install, tighten to 11 Nm (8 lb-ft). 4. To install, reverse the removal procedure. 5. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1214 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1215 procedure again. - RH side shown, LH similar. 1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. NOTE: Make sure the second row safety belt retractor belt webbing is not twisted prior to installation. Remove the bolt and second row safety belt retractor anchor. To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips to access the C-pillar side impact sensor. 6. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the side impact sensor locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the side impact sensor bolt. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the removal procedure. 9. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1216 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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: - Avoid applying corrosion protection to any safety, mechanical and electrical parts, electric motors, speakers, door locks and drain holes. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1217 3. Separate the weathershield from the door 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 screws is critical for correct system operation. 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 tab for installation. Remove the 2 screws and side impact sensor. To install, tighten to 3 Nm (27 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 1222 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 1225 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 1226 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Raise the driver seat and then position it to the rear of the track. 2. Depower the system. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the seat position sensor electrical connector and remove the seat position sensor and bracket. 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1236 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1243 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1250 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1254 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 1265 RH Side Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the senor harness from the sensor bracket. 3. Disconnect the sensor electrical connector. 4. Disconnect the sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 sensor bolts. ^ To install, tighten to 11 Nm (8 lb-ft). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1269 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1274 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1277 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1278 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1279 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1280 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1281 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1282 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1289 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1290 orientation. 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 (2007)) 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 1291 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1292 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1293 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1294 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1295 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1296 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1297 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1298 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1299 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1300 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1301 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1302 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1303 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1304 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1305 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 1306 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1311 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1312 orientation. 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 (2007)) 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 1313 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1314 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1315 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1316 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1317 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1318 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1319 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1320 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1321 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1322 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1323 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1324 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1325 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1326 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1327 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1332 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1333 orientation. 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 (2007)) 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 1334 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1335 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1336 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1337 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1338 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1339 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1340 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1341 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1342 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1343 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1344 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1345 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1346 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1347 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1348 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1354 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1355 orientation. 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 (2007)) 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 1356 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1357 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1358 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1359 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1360 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1361 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1362 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1363 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1364 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1365 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1366 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1367 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1368 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1369 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1370 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1371 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1372 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 1375 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1380 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1381 orientation. 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 (2007)) 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 1382 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1383 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1384 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1385 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1386 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1387 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1388 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1389 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1390 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1391 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1392 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1393 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1394 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1395 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1396 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1401 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1402 orientation. 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 (2007)) 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 1403 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1404 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1405 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1406 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1407 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1408 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1409 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1410 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1411 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1412 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1413 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1414 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1415 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1416 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1417 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 orientation. 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1443 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1449 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1450 View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1451 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1454 C535A C535B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1455 C701 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1456 C801 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1457 Power Window Switch: Diagrams Power Window Switch, RH Side Front C624 C648 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1460 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1461 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1462 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1463 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1464 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1465 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. Unlock the tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1470 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1474 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1477 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1478 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1479 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1480 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1481 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1482 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1486 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1489 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1490 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1491 Wiper Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1492 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1493 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1494 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1500 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1501 Alignment: Specifications Ride Height Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1502 Part 2 Of 3 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1503 Alignment: Specifications Alignment Specifications Vehicles With Rear Coil Spring Suspension Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1504 Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1505 Alignment: Specifications Alignment Specifications Vehicles With Rear Air Suspension Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1506 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1507 Alignment: Specifications Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1508 Part 2 Of 2 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1509 Part 2 Of 3 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1510 Alignment Specifications Vehicles With Rear Coil Spring Suspension Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1511 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1512 Alignment Specifications Vehicles With Rear Air Suspension General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1513 General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1514 General Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1515 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 removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct affect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting does not affect tire wear. Toe Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1516 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1517 Front Ride Height Measurement Rear Ride Height Measurement 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 (2007)) 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 kit (3B236 for the front and 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. NOTE: The lower arm front and rear bolts must be tightened with the weight of the vehicle resting on the wheel and tire assembles. While holding the cam bolt, tighten the nut to 350 Nm (258 lb-ft). 6. Check and, if necessary, adjust the front toe. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 1520 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod. Rotate the tie rod(s) to achieve the desired toe setting.! 7. 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 115 Nm (85 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 1521 8. Install the steering gear bellows clamp(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 1522 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. NOTE: Before carrying out a toe adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link cam bolt nut(s). 3. Rotate the toe link cam bolt(s) until the toe setting is within specification. 4. NOTE: Make sure the toe settings are not disturbed while tightening the cam nut(s). Tighten the toe link cam bolt nut(s) to 275 Nm (203 lb-ft). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 1523 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear camber. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear camber value is not within specification, go to the next step. 2. Remove the upper arm-to-frame bolt and the camber set shim. ^ Discard the camber set shim. ^ Install and snug the upper arm-to frame bolt. 3. Position the upper arm-to-frame bolt in the upper arm-to-frame slot until the camber setting is within specification. 4. NOTE: Do not allow the upper arm to move and change the camber adjustment setting when tightening the bolt. Tighten the upper arm-to-frame bolt to 300 Nm (221 lb-ft). 5. Recheck the camber setting, adjust as necessary. 6. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 1524 Alignment: Service and Repair Ride Height Adjustments (Vehicle Dynamic Suspension) Ride Height Adjustments Special Tool(s) CAUTION: The suspension height D dimensions are for reference only. The vehicle attitude must be controlled by the correct dimensions to prevent vehicle damage. NOTE: If one or both height sensors are installed new, both height sensors must be calibrated. NOTE: Incorrect air suspension ride height D dimension can be caused by an air suspension system that is incorrectly set. NOTE: The air suspension module has a preprogrammed trim height. 1. NOTE: The vehicle must be on a level surface, such as a drive on alignment hoist. Position the vehicle on a level surface. 2. Using the vehicle message center, verify that the air suspension is in the ON mode. 3. Using the scan tool, run the accurate trim test. 4. Measure the ride height D dimension. 5. If ride height dimension D is not within specification, use the scan tool to vent or fill the air suspension to the correct dimension. 6. NOTE: The air suspension height sensor sends a signal to the air suspension module. The output ranges from approximately 4.5 volts at minimum height (when the vehicle is low or in full jounce) to 0.5 volt at maximum height (when the vehicle is in high or in full rebound). Using the scan tool, monitor the 2 suspension height sensors voltage parameter identifications (PIDs). 7. Using the scan tool, save the vehicle's trim height for both sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1. Disconnect the battery ground cable. 2. Disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the air cleaner element. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1536 Installation 1. CAUTION: The air cleaner element must be fully seated into 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 (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1544 Firing Order: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: Customer Interest Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 1557 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1563 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1564 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1565 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1566 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1567 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1568 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1569 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1570 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1571 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1572 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1573 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: All Technical Service Bulletins Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 1578 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1584 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1585 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1586 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1587 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1588 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1589 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1590 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1591 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1592 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1593 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 1594 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1595 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1596 Spark Plug: Application and ID Spark plug ........................................................................................................................................... ....................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1597 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1598 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1599 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1600 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: - Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior to spark plug removal. - Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - 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 (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1604 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1605 leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1617 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1623 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1624 Drive Belt: Locations Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1625 Drive Belt: Diagrams Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1626 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 (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 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 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. 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% 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1629 V-Ribbed Serpentine Belt With Piling 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. V-Ribbed Serpentine Belt With Chunks of Rib Missing 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 (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1630 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1631 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1632 Drive Belt: Component Tests and General Diagnostics Drive Belt - Noise/Flutter 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 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 reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ 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. Drive Belt - Incorrect Installation Drive Belt - Incorrect 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 (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1633 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: ^ 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 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 a 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 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 (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1634 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 (2007)) 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 1. Disconnect the battery ground cable. 2. Disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the air cleaner element. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1640 Installation 1. CAUTION: The air cleaner element must be fully seated into 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 (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 1647 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 1648 Exploded View Removal and Installation 1. NOTE: The evaporative emission canister vent solenoid and dust separator are an assembly. This assembly is removed with the evaporative emission canister vent solenoid. Refer to Evaporative Emission Canister Vent Solenoid. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Leak Detection Valve/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Material Removal 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the fluid to drain. 4. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1652 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case, carefully remove the seal without scratching the case. 2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean automatic transmission fluid. 3. NOTE: The fluid filter may be reused if no excessive contamination is indicated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1653 Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. 6. Install the fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the refill procedure, fill and check the transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Refrigerant Filter: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1666 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1667 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1668 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Refrigerant Filter: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1674 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1675 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1676 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 1686 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 (2007)) 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 1687 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 (2007)) 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 (2007)) 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 1693 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 (2007)) 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 1694 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 (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures Heater Hose: Procedures HEATER HOSE COUPLING Special Tool(s) 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 (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures > Page 1697 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 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 (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures > Page 1698 Heater Hose: Removal and Replacement AUXILIARY HEATER OUTLET AND INLET LINE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures > Page 1699 Part 2 Removal NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. - The following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the RH fender splash shield. 5. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s). 6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition EL or Navigator L only 8. Remove the RH rear wheel and tire assembly. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures > Page 1700 9. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s). 10. Remove the muffler. 11. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 12. Remove the 3 muffler heat shield bolts and the muffler heat shield. 13. Remove the 2 exhaust hanger bolts and the exhaust hanger. 14. Remove the RH catalyst monitoring sensor. 15. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 16. Remove the 3 remaining auxiliary line bracket nuts and the line brackets. 17. 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). 18. Remove the auxiliary heater line(s) in 3 separate pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings. All vehicles 2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings. 3. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). 4. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 5. Tighten the middle auxiliary heater line fittings. 6. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 7. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts. 8. Install the RH catalyst monitoring sensor. 9. Install the exhaust hanger and the 2 exhaust hanger bolts. 10. Install the muffler heat shield and the 3 muffler heat shield bolts. 11. Install the muffler. 12. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 13. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 14. Install the front auxiliary line bracket and the front auxiliary line bracket and nut. - Tighten to 5 Nm (44 lb-in). 15. Install the RH front fender splash shield. 16. Install the RH front wheel. Expedition EL or Navigator L only 17. Install the RH rear wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Procedures > Page 1701 All vehicles 18. Install the spare tire. 19. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Hose/Line HVAC: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1710 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1711 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1712 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Hose/Line HVAC: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1718 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1719 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 1720 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1721 Hose/Line HVAC: Description and Operation AUXILIARY A/C - HEATER LINES The auxiliary lines are secured to the underbody of the vehicle. Each auxiliary line is only available as a multiple-piece kit for ease of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1724 Part 2 Removal NOTE: - The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly for Expedition or Navigator vehicles. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. - The auxiliary evaporator inlet and outlet lines for Expedition EL or Navigator L vehicles are installed from the factory as a single one-piece assembly including both lines. The replacement part is supplied as a multiple-piece kit for ease of installation. - For Expedition or Navigator vehicles, the following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. For Expedition EL or Navigator L vehicles, both lines must be removed. - Installation of a new receiver/drier cartridge 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 cartridge. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the auxiliary evaporator outlet and inlet line front fitting nut(s) and disconnect the fitting(s). Discard the O-ring seals and gasket seals. 4. Remove the spare tire. 5. Remove the RH fender splash shield. 6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1725 7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition or Navigator only 8. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the auxiliary evaporator outlet and inlet line rear fittings. Discard the O-ring seals. Expedition EL or Navigator L only 9. Remove the RH rear wheel and tire assembly. 10. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. - Discard the gasket seals. All vehicles 11. Remove the muffler. 12. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 13. Remove the 3 muffler heat shield bolts and the heat shield. 14. Remove the 2 exhaust hanger bolts and the exhaust hanger. 15. Remove the RH catalyst monitoring sensor. 16. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 17. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary 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). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1726 19. NOTE: - Expedition EL shown. - For Expedition EL or Navigator L vehicles, the middle portion of the auxiliary evaporator outlet and inlet lines can be removed through the RH rear wheel well opening between the body and the frame. Remove the auxiliary evaporator line(s) in 3 separate pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary evaporator line(s) and connect the auxiliary evaporator outlet and inlet line rear fittings. - Install new O-ring seals. Expedition EL or Navigator L only 2. Install the rear portion of the auxiliary evaporator outlet and inlet line. 3. Connect the auxiliary evaporator outlet and inlet line rear fitting and install the nut. - Install new gasket seals. - Tighten to 12 Nm (9 lb-ft). All vehicles 4. Install the front portion of the auxiliary evaporator outlet and inlet line(s). 5. Connect the evaporator outlet and inlet line front fitting(s) and install the nut(s). - Install new O-ring seals and gasket seals. - Tighten to 15 Nm (11 lb-ft). 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 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1727 8. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar. 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 RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts. 11. Install the exhaust hanger and the 2 exhaust hanger bolts. 12. Install the muffler heat shield and the 3 muffler heat shield bolts. 13. Install the RH catalyst monitoring sensor. 14. Install the muffler. 15. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 16. Install the front auxiliary line bracket and the front auxiliary line bracket nut. - Tighten to 5 Nm (44 lb-in). 17. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 18. Install the RH front fender splash shield. 19. Install the RH front wheel. Expedition EL or Navigator L only 20. Install the RH rear wheel and tire assembly. All vehicles 21. Install the spare tire. 22. Lubricate the refrigerant system with the correct amount of clean PAG oil. 23. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1728 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation NOTE: Installation of a new receiver/drier cartridge 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 cartridge. 1. Recover the refrigerant. 2. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the condenser inlet jumper line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the compressor-to-condenser discharge line. 5. If removing the condenser inlet jumper line, remove the RH headlamp assembly. 6. If removing the condenser inlet jumper line, disconnect the A/C pressure transducer electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1729 7. If removing the condenser inlet jumper line, remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (11 lb-ft). 8. Remove the condenser inlet jumper line. 9. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose 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. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the upper air deflector. 1 Remove the 10 upper air deflector pushpin-type retainers. 2 Remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1734 3. Remove the air cleaner outlet pipe. 4. Release the clamp and disconnect the power steering return hose from the power steering fluid cooler. 5. Release the power steering return hose from the cooling fan shroud clips. 6. Release the lower cooling fan shroud tab and rotate the shroud upward. 7. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering return line from the power steering gear. ^ To install, tighten to 23 Nm (17 lb-ft). ^ Discard the steering line O-ring seals. 9. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1735 Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1736 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1737 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. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. 1. Remove the power steering pump pulley. 2. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 lb-ft). 3. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. Disconnect the power steering pressure line-to-power steering pump fitting. ^ Discard the Teflon O-ring seal. ^ To install, tighten to 65 Nm (48 lb-ft). 4. Remove the power steering pressure line bracket-to-crossmember bolt. ^ To install, tighten to 6 Nm (53 lb-in). 5. Remove the power steering pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1738 6. NOTE: A new O-ring seal must be installed any time the power steering line is disconnected from the power steering gear. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering line. ^ Discard the O-ring seals. ^ To install, tighten to 23 Nm (17 lb-ft). 7. NOTE: A new O-ring seal must be installed any time the power steering line is disconnected from the power steering gear. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring on the pressure line-to-pump fitting and pressure line-to-steering gear. 8. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. .................................................................. PM-1-C Ford Specification ............................................... ..................................................................................................................................... WSS-M6C62-A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM BASE RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 20.6 quarts (19.5 liters) With aux rear heat ................................................ ....................................................................................................................... 23.2 quarts (22.0 liters) HEAVY DUTY TRAILER TOW RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 21.1 quarts (20.0 liters) With aux rear heat ................................................ ....................................................................................................................... 23.8 quarts (22.5 liters) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1747 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N .............................................................................................................................................. .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid (6R75) .................................................................................................................. ............................................. 11.0 quarts (10.5 liters) NOTE: Indicates only approximate dry fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1752 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... .......................................... MERCON SP XT-6-QSP Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 6HP26 Automatic Transmission Fluid - A/T: Testing and Inspection 6HP26 Automatic Transmission 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: 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 PARK, the engine at idle (550-750 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 PARK position. 2. With the engine idling (550-750 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 lb-ft). 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 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 amber. 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 6HP26 Automatic Transmission > Page 1755 Fluid - A/T: Testing and Inspection 6R75 Automatic Transmission 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. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. This transmission is equipped with an internal thermal bypass located in the case. This internal thermal bypass valve will shut off fluid flowing to the fluid cooler if the fluid temperature falls below normal operating temperature. High Fluid Level CAUTION: 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 cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission failure. If an overfill reading is indicated, remove any excessive fluid. 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. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. 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. Add fluid using the refill procedure. Fluid Condition Check 1. Check the fluid level. 2. Remove the fluid fill plug and fluid level indicator and allow the fluid to drip onto a facial tissue and examine the stain. 3. Observe the color and the odor. The color under normal circumstances should be dark reddish, 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. new oil-to-air (OTA) cooler must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill 6HP26 Automatic Transmission Transmission Fluid Drain and Refill Special Tool(s) Material Drain 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 the transmission fluid pan and allow the fluid to drain. 3. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1758 4. Clean and inspect the transmission fluid pan and magnet. Refill 1. Install the fluid pan gasket. 2. Install the fluid pan and bolts. ^ Tighten to 12 Nm (9 lb-ft). 3. 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. 4. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1759 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. 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 (550-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level. 7. 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 with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. 8. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). 6R75 Automatic Transmission Transmission Fluid Drain and Refill Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1760 Special Tool(s) Material Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some fluid leakage may occur when removing the fluid fill plug. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1761 3. Remove the transmission fluid pan and allow the fluid to drain. 4. Install the transmission fluid pan. ^ Tighten to 14 Nm (10 lb-ft). Transmission Fluid Refill CAUTION: This procedure contains the air purge steps required to purge air from the cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. 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. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. ^ Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill enabling you to start the engine. ^ The cold level range shown in the procedure allows the vehicle to be driven. ^ The vehicle should be driven to allow the transmission fluid temperature to reach 85°C-88°C (185°F-190°F) in order to purge the air from the transmission cooling system. ^ Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range 80°C-85°C (175°F-185°F). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to the transmission as an initial fill if: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1762 ^ the transmission has been overhauled. ^ a new mechatronic assembly has been installed. ^ the transmission fluid pan or fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission through the fluid fill hole. 2. Check the transmission fluid level cold. 1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90°F-110°F). ^ Using the scan tool and the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm). 3. Separate the fluid level indicator from the fill plug. 4. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 5. Add clean transmission fluid to the cold level location as shown in the illustration. 6. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1763 7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the cooling system, eliminating any trapped air in the cooling system. ^ With the engine idling (600-750 rpm) in PARK, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). 8. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. 9. Separate the fluid level indicator from the fill plug. 10. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 11. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1764 12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid in this procedure. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the special tool into the fluid fill hole. 2. Fill the special tool with approximately 0.47L (1 pt) of clean automatic transmission fluid. 3. Hang the special tool under the vehicle, upright and close to the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1765 4. Connect the special tools. ^ Connect the open end of the fluid hose from the special tool onto the special tool from the transmission case. 5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission. 6. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 7. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1766 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Removing Transmission Fluid NOTE: To get an accurate fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, fluid must be removed to the correct level. Use the special tools to extract any excessive fluid. 2. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 3. Install the fluid fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1767 ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1768 Fluid - A/T: Service and Repair Transmission Fluid Level Check Transmission Fluid Level Check Special Tool(s) Material CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler, cooler lines have been carried out the vehicle must be driven to get the transmission fluid to a temperature of 88°C (190°F) in order to purge the air from the cooling system. 1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK. 2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the fluid level indicator from the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1769 5. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. 6. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. 7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1770 Fluid - A/T: Service and Repair 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 leaks 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 fluid cooler 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. 6R75 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 leaks 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1771 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 (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1776 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 (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1781 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1782 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling Special Tool(s) Material 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 lb-ft). 2. Clean the area around the fill plug. Remove the fill plug. 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 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1787 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 (2007)) 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1792 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1793 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89L (2 qt) of power steering fluid. For steering system fluid capacity, refer to Specifications. 10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the bellows boot clamp from the steering gear bellows boots to inspect for internal steering gear leaks. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1798 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 (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1799 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. 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. Refer to Heating and Air Conditioning. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1804 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL TYPE (R-134a Systems) PAG Refrigerant Compressor Oil Ford P/N ........................................................... .................................................................................................................................................. YN-12-D Ford Specification ................................................................................................................. ................................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1809 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1810 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1811 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1812 Brake Bleeding: Service and Repair Gravity Gravity 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. ^ Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1813 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1814 Brake Bleeding: Service and Repair Manual Manual 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1815 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1816 Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1817 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1818 with pressure bleeding equipment. NOTE: This procedure must be performed if the anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Gravity Gravity Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1819 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1820 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1821 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 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1822 NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough clean, 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 clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified 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. 8. Fill the brake master cylinder reservoir with clean, specified brake fluid and install the brake master cylinder filler cap. Master Cylinder, Bench Master Cylinder, Bench Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1823 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 1824 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 (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1829 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1830 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1831 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1832 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1833 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1834 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1835 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1836 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1837 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1838 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1839 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1840 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1841 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1847 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1848 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1849 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1850 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1851 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1852 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1853 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1854 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1855 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 1856 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 orientation. 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 (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1878 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1879 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1880 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1881 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1882 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1883 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1884 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1885 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1886 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1887 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1892 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1893 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1894 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1895 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1896 Fuse Block: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1897 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1898 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1899 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1900 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 1901 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 orientation. 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 (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Fuse Block: Connector Views C1035 C2280A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 C2280B C2280C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1929 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1930 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1931 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1932 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1933 Fuse Block: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1934 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1935 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1936 Fuse Block: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1937 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 1938 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1943 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1944 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1945 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1946 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1947 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1948 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1949 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1950 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1951 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 1952 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1955 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1956 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1957 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1958 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1959 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1962 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1963 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1964 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1965 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1966 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1967 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1968 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1969 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1970 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 1971 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS 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. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out the following procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire (as necessary). 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions: 1. 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 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB 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 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. 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 (2007)) 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 (2007)) 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) 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. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 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. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair CHANGE OIL SOON/OIL CHANGE REQUIRED Displayed when the engine oil life remaining is 5 percent or less. When oil life left is between 5% and 0%, the CHANGE OIL SOON message will be displayed. When oil life left reaches 0%, the OIL CHANGE REQUIRED message will be displayed. An oil change is required whenever indicated by the message center and according to the recommended maintenance schedule. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Press and release the SETUP control to display "OIL LIFE=XXX% HOLD RESET=NEW ". 2. Press and hold the RESET control for 2 seconds and release. Oil life is set to 100% and "OIL LIFE SET TO 100%" is displayed. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the instrument cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 100% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) NOTE:All message center functions are carried out using the single stem reset button in the instrument cluster (IC). NOTE:The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE:The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. - 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. Disable the air suspension system. Refer to Electronic Level Control. Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1989 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. CAUTION: 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. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. LIFTING WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. 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. Disable the air suspension system. Refer to Electronic Level Control. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1990 Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 1995 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1998 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1999 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2000 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2001 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2002 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2003 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS 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. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out the following procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire (as necessary). 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions: 1. 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 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB 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 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2011 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2014 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2015 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2016 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2017 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2018 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 2019 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 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 (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2028 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 (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2029 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 (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2030 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 (2007)) 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 (2007)) 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 2036 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 (2007)) 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 2037 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 (2007)) 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 2038 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 (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2043 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. Disconnect the wheel speed sensor electrical connector. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the wheel speed sensor harness bolt and detach the harness from the retainers. ^ To install, tighten to 12 Nm (9 lb-ft). 4. 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 brake caliper and anchor plate assembly aside. ^ Support the brake caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the halfshaft nut dust cap. 7. Remove and discard the halfshaft nut. ^ To install, tighten to 27 Nm (20 lb-ft). 8. Remove the 4 wheel bearing and wheel hub bolts and the wheel hub. ^ To install, tighten to 185 Nm (136 lb-ft). 9. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 18 Nm (13 lb-ft). 10. CAUTION: If the original wheel bearing and wheel hub is being installed, install a new wheel hub O-ring seal. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2044 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. ^ To install, tighten to 300 Nm (221 lb-ft). 3. Using a suitable hub puller, separate the outboard CV joint from the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2045 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 190 Nm (140 lb-ft). 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 wheel bearing and wheel hub bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake disc shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 lb-ft). 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. ^ To install, tighten to 18 Nm (13 lb-ft). 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Front Front Axle nut....................................................................................................................................... ......................................................... 27 Nm (20 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 2051 Axle Nut: Specifications Rear Rear axle Nut ....................................................................................................................................... .................................................... 300 Nm (221 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 2055 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Page 2059 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts............................................................................................................................................ ..................................................... 204 Nm (150 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2063 Wheel Fastener: Service and Repair Wheel Studs Special Tool(s) 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. 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 (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2064 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. - 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. Disable the air suspension system. Refer to Electronic Level Control. Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2068 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. CAUTION: 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. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. LIFTING WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. 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. Disable the air suspension system. Refer to Electronic Level Control. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2069 Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2077 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2078 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 VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2079 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 (2007)) 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 (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the variable camshaft timing (VCT) oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2086 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2087 leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 2095 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 (2007)) 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 Bearing Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. ^ If out of specification, install new components as necessary. Camshaft Journal to Bearing Clearance Special Tool(s) NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage(R) 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(R) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2100 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 Surface Inspection 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 Tool(s) 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2101 Camshaft Runout 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. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2102 Camshaft: Service and Repair Camshaft - LH Camshaft - LH Valve Train Components - Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2103 Special Tool(s) Material Removal CAUTION: 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. CAUTION: 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. 4. Disconnect the LH camshaft position (CMP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2104 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. 7. Remove only the 3 camshaft roller followers shown in the illustration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2105 8. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. 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. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2106 10. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. CAUTION: 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. CAUTION: 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. CAUTION: 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. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2107 12. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from side loading when removing the cam unequally in height from the bearing towers. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the front camshaft bearing cap and then the remaining bearing caps. 13. 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. 14. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2108 CAUTION: 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. 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. 15. Inspect the camshaft phaser and sprocket for damage. Installation 1. Lubricate the camshaft and camshaft journals with clean engine oil. 2. CAUTION: 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. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: 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. CAUTION: 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. CAUTION: 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2109 4. CAUTION: 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 inch lbs.) 6. NOTE: Engine front cover removed for clarity. Remove the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2110 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. Using the special tool, install the 3 originally removed camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2111 10. Install the CMP sensor and the bolt. 11. Connect the CMP electrical connector. 12. CAUTION: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. CAUTION: 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 ft. lbs.) ^ Stage 2: Tighten an additional 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2112 13. Install the LH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2113 Camshaft: Service and Repair Camshaft - RH Camshaft - RH Valve Train Components - Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2114 Special Tool(s) Material Removal CAUTION: 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. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn. 4. Disconnect the RH camshaft position (CMP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2115 5. Remove the bolt and the RH CMP sensor. 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2116 8. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. 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. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. 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. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2117 CAUTION: 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. CAUTION: 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. CAUTION: 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. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from sideloading when removing the cam unequally in height from the bearing towers. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the front camshaft bearing cap and then the remaining bearing caps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2118 13. 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. 14. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. CAUTION: 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2119 15. Inspect the camshaft phaser and sprocket for damage. Installation 1. Lubricate the camshaft and camshaft journals with clean engine oil. 2. CAUTION: 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. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: 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. CAUTION: 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. CAUTION: 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. Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment. 4. CAUTION: 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2120 ^ Install the bolts loosely. 5. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.) 6. NOTE: Engine front cover removed for clarity. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2121 8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes. 9. 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 inch lbs.) 11. Connect the CMP electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2122 12. CAUTION: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. CAUTION: 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 ft. lbs.) ^ Stage 2: Tighten an additional 90 degrees. 13. Install the RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2123 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 2124 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 2128 Lifter / Lash Adjuster: Service and Repair 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection Rocker Arm Assembly: Testing and Inspection 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2132 Rocker Arm Assembly: Service and Repair 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2133 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 (2007)) 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 (2007)) 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 2138 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2139 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 VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2140 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Bore diameter (with assembled liners)............................................................................................................... 53.049-53.027 mm)(2.0885-2.0877 inch) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2145 Connecting Rod Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for these 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Rod-to-pin clearance............................................................................................................................................. 0.009-0.0235 mm (0.0004-0.0093 inch) Pin bore diameter................................................................................................................................................ 22.012-22.024 mm (0.8666-0.8671 inch) Length (center-to-center).................................................... .......................................................................................................... 169.1 mm (6.6575 inch) Maximum allowed bend........................................................................................................................ .................................... ± 0.038 mm (0.0015 inch) Maximum allowed twist(a)..................................... ..................................................................................................................... ± 0.05 mm (0.0020 inch) Rod bearing Bore diameter (with assembled liners)......................................................................................................... 53.049-53.027 mm)(2.0885-2.0877 inch) 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) (a) 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 Bolts Discard the bolts. First pass ............................................................................................................................................. ................................................. 43 Nm (32 ft. lbs.) Final pass ............................................................. .......................................................................................................................................... Tighten 105° Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2149 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 2 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. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped. 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2150 Connecting Rod Bend 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-to-Piston 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-to-Bearing Clearance Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2151 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(R) 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(R) to get the connecting rod bearing journal clearance. The Plastigage(R) 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. Connecting Rod Bearing Journal Taper and Out-of-Round 1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2152 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Discard the crankshaft pulley bolt. 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 (2007)) 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..................................................................................................................... 0.0075 mm (0.0003 inch) between cross sections 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..................................................................................................................... 0.0075 mm (0.0003 inch) between cross sections Crankshaft maximum end play................................................................................................................................ 0.075-0.377 mm (0.0030-0.0148 inch) Main Bearing Size Codes Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2159 Vertical Main Bearing Cap Fasteners Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2160 First pass ............................................................................................................................................. ................................................. 40 Nm (30 ft. lbs). Final pass ............................................................. ............................................................................................................................................ Tighten 90° Side Bolts First pass ............................................................................................................................................. ................................................. 30 Nm (22 ft. lbs). Final pass ............................................................. ............................................................................................................................................ Tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2161 Crankshaft Main Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for these 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 (2007)) 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..................................................................................................................... 0.0075 mm (0.0003 inch) between cross sections 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..................................................................................................................... 0.0075 mm (0.0003 inch) between cross sections Crankshaft maximum end play................................................................................................................................ 0.075-0.377 mm (0.0030-0.0148 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2165 Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions. ^ If out of specification, install new components as necessary. Crankshaft Main Bearing Journal Taper and Out-of-Round 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal. ^ If out of specification, install new components as necessary. Crankshaft Main Bearing Journal-to-Bearing Clearance 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. 2. Lay a piece of Plastigage(R) across the face of each crankshaft main bearing surface. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2166 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 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. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2167 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Discard the crankshaft pulley bolt. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2174 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2175 Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Release the cooling fan shroud position tab and rotate the shroud upward until the lower tab locks into position. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2176 Installation 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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 degrees. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2177 ^ Stage 4: Tighten an additional 90 degrees. 5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. 6. Release the cooling fan shroud position tab and rotate the shroud downward until the tab locks into position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 c ontrol..................................................................................................................................................... ........ 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 c ontrol..................................................................................................................................................... .... 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) Length............................................................................. ............................................................................................................. 61.8 mm (2.433 inch) Pin-to-piston fit................................................................................................................................................. 0.005-0.013 mm (0.0002-0.0005 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston Inspection 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 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 2 directions on each side. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2183 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 1. 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. 1. Select a piston size based on the cylinder bore. 2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot on the new pistons indicates the position within the size range. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2184 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2185 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 2 directions at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2186 Piston: Overhaul 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 1. NOTE: The connecting rod must be installed into the piston with identification markings toward the front. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2187 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 (2007)) 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 c ontrol..................................................................................................................................................... ........ 0.15-0.65 mm (0.0059-0.0256 inch) 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 c ontrol..................................................................................................................................................... .... 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 (2007)) 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 lash adjusters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection Rocker Arm Assembly: Testing and Inspection 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2201 Rocker Arm Assembly: Service and Repair 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2202 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 (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2207 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2208 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2209 Removal 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the degas bottle. For additional information, refer to Cooling System. 3. Remove the LH ignition coils. For additional information, refer to Ignition System. 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 LH radio ignition interference capacitor electrical connector. 7. Disconnect the LH 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. Disconnect the intake manifold vacuum tube assembly from the support bracket and the valve cover stud and position aside. 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. CAUTION: When removing the valve cover, make sure to avoid damaging the VCT solenoid. NOTE: The fasteners are part of the valve cover and should not be removed. Fully 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. ^ 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. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid. Position the LH valve cover and new gasket on the cylinder head and tighten the fasteners in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2210 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. Install the LH ignition coils. For additional information, refer to Ignition System. 10. Install the degas bottle. 11. Install the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2211 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2212 Removal All vehicles 1. Recover the refrigerant. For additional information, refer to Heating and Air Conditioning. Vehicles with auxiliary heat 2. Drain the cooling system. For additional information, refer to Cooling System. 3. Disconnect the 2 auxiliary heat coolant hoses. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2213 4. Disconnect the coolant hose from the intake manifold and position the coolant hose assembly aside. All vehicles 5. Disconnect the quick connect couplings and remove the crankcase vent tube. For additional information, refer to Fuel Delivery and Air Induction. 6. Remove the nut and the ground cable and disconnect the wiring harness retainer. 7. Disconnect the powertrain control module (PCM) electrical connector. 8. Disconnect the 2 electrical connectors and the wiring harness retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2214 9. Disconnect the evaporator outlet and inlet fittings. ^ Discard the O-ring seals. 10. Disconnect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors. 11. Remove the RH ignition coils. For additional information, refer to Ignition System. 12. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector. 13. Disconnect the RH camshaft position (CMP) sensor electrical connector. 14. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs. 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. CAUTION: When removing the valve cover, make sure to avoid damaging the VCT solenoid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2215 NOTE: The fasteners are part of the valve cover and should not be removed. Fully 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 All vehicles 1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid. Position the LH valve cover and new gasket on the cylinder head and tighten the fasteners in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.) 3. Install the RH ignition coils. For additional information, refer to Ignition System. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2216 4. Using new O-ring seals, connect the evaporator outlet and inlet fittings. ^ Lubricate the O-ring seals with PAG oil prior to installation. 5. Connect the 2 electrical connectors and the wiring harness retainer. 6. Connect the PCM electrical connector. 7. Connect the wiring harness retainer and ground cable and install the nut. ^ tighten to 10 Nm (89 inch lbs.) 8. Connect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2217 9. Connect the RH VCT solenoid electrical connector. 10. Connect the wiring harness retainers to the valve cover. 11. Position the crankcase vent tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. Vehicles with auxiliary heat 12. Position the coolant hose assembly and connect the coolant hose to the intake manifold. 13. Connect the 2 auxiliary heat coolant hoses. 14. Fill and bleed the coolant system. All vehicles 15. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve Guide Inner Diameter 1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide if necessary. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide. 2. Measure the ball gauge with a micrometer. 3. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair Valve Seat: Service and Repair 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. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Inspection Valve Spring: Service and Repair Valve Spring Inspection 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Inspection > Page 2228 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Inspection > Page 2229 Valve Spring: Service and Repair Valve Springs Valve Springs Special Tool(s) Material 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Inspection > Page 2230 7. Remove the valve spring retainer and the valve spring. 8. Inspect the valve spring. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection Valve: Testing and Inspection Valve Inspection 1. Inspect these valve areas: 1 the end of the stem for grooves or scoring 2 the valve face and the edge for pits, grooves or scores 3 the valve head for signs of burning, erosion, warpage and cracking 4 the valve margin for wear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Page 2234 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 Stem to Valve Guide Clearance 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2244 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2250 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2251 Drive Belt: Locations Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2252 Drive Belt: Diagrams Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2253 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 (2007)) 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 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 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. 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% 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2256 V-Ribbed Serpentine Belt With Piling 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. V-Ribbed Serpentine Belt With Chunks of Rib Missing 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 (2007)) 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 2257 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2258 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2259 Drive Belt: Component Tests and General Diagnostics Drive Belt - Noise/Flutter 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 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 reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ 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. Drive Belt - Incorrect Installation Drive Belt - Incorrect 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 (2007)) 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 2260 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: ^ 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 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 a 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 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2261 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Removal and Installation 1. Remove the cooling fan. For additional information, refer to Cooling System. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the A/C compressor 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Engine Support Insulators Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2268 LH Engine Support Insulator Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2269 RH Engine Support Insulator Removal All engine support insulators 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 throttle body (TB). For additional information, refer to Fuel Delivery and Air Induction. 4. Remove the cooling fan. For additional information, refer to Cooling System. 5. Remove the generator. For additional information, refer to Alternator. 6. Remove the starter. For additional information, refer to Starting System. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2270 7. If servicing the engine support insulators on a four wheel drive (4WD) vehicle, remove the front drive shaft. 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. RH engine support insulator 11. CAUTION: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the LH engine support insulator through bolt. 12. CAUTION: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the RH engine support insulator through bolt. 13. CAUTION: Only use hand tools when removing the engine support insulator nuts or damage to the engine support insulator can occur. NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the nut from the stud bolt prior to stud bolt installation. Remove the 2 RH engine support insulator nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2271 14. CAUTION: Only use hand tools when removing the engine support insulator stud bolts or damage to the engine support insulator can occur. Remove the 2 RH engine support insulator stud bolts. 15. Using the special tools, raise the engine. 16. Remove the 3 bolts and the RH engine support insulator-to-cylinder block bracket. 17. Remove the RH engine support insulator. LH engine support insulator 18. CAUTION: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the RH engine support insulator through bolt. 19. CAUTION: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the LH engine support insulator through bolt. 20. Using the special tools, raise the engine. 21. CAUTION: Only use hand tools when removing the engine support insulator-to-frame bolts or damage to the engine support insulator-to-frame nut plate can occur. Remove the 3 engine support insulator-to-frame bolts. ^ Discard the 3 bolts. 22. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket. 23. Remove the LH engine support insulator. 24. Inspect the engine support insulator-to-frame nut plate for thread damage. If the nut plate is damaged, bend 2 tabs back and remove the nut plate. Replace the nut plate with service part number 56190 and bend the 2 tabs back to the original position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2272 Installation RH engine support insulator 1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation. 2. CAUTION: Only use hand tools when installing the engine support insulator stud bolts or damage to the engine support insulator can occur. Position the RH engine support insulator into the vehicle and install the 2 stud bolts. ^ Tighten to 15 Nm (11 ft. lbs.) 3. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts. ^ Tighten to 63 Nm (46 ft. lbs.) 4. CAUTION: Only use hand tools when installing the RH engine support insulator nuts or damage to the engine support insulator can occur. Install the 2 RH engine support insulator nuts. ^ Tighten to 175 Nm (129 ft. lbs.) LH engine support insulator 5. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation. 6. Position the LH engine support insulator and hand start the 3 new engine support insulator-to-frame bolts. ^ Tighten to 175 Nm (129 ft. lbs.) 7. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts. ^ Tighten to 63 Nm (46 ft. lbs.) All engine support insulator 8. Using the special tools, lower the engine into position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2273 9. CAUTION: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur. Install the LH and RH engine support insulator bolts. ^ Apply Threadlock 262 to the bolt threads prior to installation. ^ Tighten to 350 Nm (258 ft. lbs.) 10. 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.) 11. Position the Y-pipe and install the 4 nuts. ^ Tighten to 40 Nm (30 ft. lbs.) 12. Remove the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2274 13. Install the starter. For additional information, refer to Starting System. 14. If servicing the engine support insulator on a 4WD vehicle, install the front driveshaft. 15. Install the generator. For additional information, refer to Alternator. 16. Install the cooling fan. 17. Install the TB. For additional information, refer to Fuel Delivery and Air Induction. 18. Connect the battery ground cable. For additional information, refer to Battery. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Idler Pulley: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2283 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Idler Pulley: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. 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 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2289 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 2295 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 2300 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 2301 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 2307 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 2312 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 2313 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 2314 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Removal and Installation 1. Remove the cooling fan. For additional information, refer to Cooling System. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the A/C compressor 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum @ 2,000 rpm (engine at normal operating temperature)............................................................................................ 517 kPa (75 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2319 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check these possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. Remove the LH exhaust manifold. 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 (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2327 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 (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2331 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 lower radiator hose from the oil filter adapter and position it aside. 4. Disconnect the degas bottle coolant hose from the oil filter adapter and position it aside. 5. Remove and discard the engine oil filter. ^ To install, tighten to 15 Nm (11 ft. lbs.) 6. Disconnect the engine oil pressure (EOP) switch electrical connector. 7. Remove the EOP switch. ^ To install, tighten to 18 Nm (13 ft. lbs.) 8. Remove the 4 bolts and the oil filter adapter. ^ To install, tighten to 25 Nm (18 ft. lbs.) 9. 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. 10. To install, reverse the removal procedure. ^ Install a new oil filter. ^ Check the engine oil level and fill as necessary with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2335 Oil Pan: Service and Repair Oil Pan Engine Lubrication Components - Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2336 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 nut and remove the starter wiring harness and transmission fluid cooler tube support brackets from the stud bolt. 5. Disconnect the starter wiring harness retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2337 Four wheel drive (4WD) vehicles 6. Support the front axle housing with a jack stand. 7. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation. Remove the front axle housing RH mounting bolt. 8. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation. Remove the front axle housing LH front mounting bolt. 9. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2338 10. 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 11. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2339 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. 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 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2340 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.) 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2341 ^ 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. Position the starter wiring harness and transmission fluid cooler tube support brackets and install the nut. ^ Tighten to 10 Nm (89 inch lbs.) 12. Connect the starter wiring harness retainer to the cylinder block. 13. Fill the crankcase with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2345 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2346 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the engine oil pressure (EOP) switch electrical connector. ^ To install, tighten to 18 Nm (13 ft. lbs.) 3. Remove the EOP switch. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Engine Lubrication Components - Exploded View Material Removal 1. Remove the oil pan. 2. Remove the 3 bolts and the oil pump screen and pickup tube. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 2350 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 (2007)) 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 @ 2,000 rpm (engine at normal operating temperature)............................................................................................ 517 kPa (75 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2355 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check these possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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.) TB Bolts First pass ............................................................................................................................................. ................................................ 9 Nm (80 inch lbs.) Final pass ............................................................ ............................................................................................................................................. Tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Intake Manifold Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2364 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2365 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2366 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2367 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. Failure to follow these instructions may result in personal injury. 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Disconnect the fuel supply hose spring lock coupling from the fuel rail. For additional information, refer to Fuel Delivery and Air Induction. 4. Remove the generator. For additional information, refer to Alternator. 5. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 6. Disconnect the crankcase ventilation tube quick connect coupling from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 7. Disconnect the quick connect coupling and remove the evaporative emissions system (EVAP) hose from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 8. Disconnect the EVAP hose position retainer from the intake manifold. 9. Remove the 4 bolts and the air cleaner outlet pipe-to-TB adapter. 10. Disconnect the heater coolant hose from the coolant bypass tube. 11. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to Fuel Delivery and Air Induction. 12. Disconnect the 8 fuel injector electrical connectors. 13. Disconnect the 8 ignition coil electrical connectors. 14. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2368 15. Disconnect the heated PCV intake fitting electrical connector. 16. Remove the intake manifold vacuum tube support bracket bolt and disconnect the intake manifold vacuum tube-to-intake manifold hose. 17. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube. 18. Disconnect the intake manifold vacuum tube support retainer from the valve cover and position the intake manifold vacuum tube aside. 19. Remove the 10 intake manifold bolts. 20. Disconnect the charge motion control valve (CMCV) electrical connector. 21. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 22. Disconnect the LH and RH knock sensor (KS) electrical connectors. 23. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud. 24. 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. Connect the engine wiring harness retainer to the CMCV stud and install the nut. ^ Tighten to 10 Nm (89 inch lbs.) 3. Connect the CMCV electrical connector. 4. Connect the CHT sensor jumper harness electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2369 5. Connect the LH and RH KS electrical connectors. 6. 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.) 7. Install the intake manifold vacuum tube support bracket bolt and connect the intake manifold vacuum tube-to-intake manifold hose. ^ Tighten to 10 Nm (89 inch lbs.) 8. Connect the intake manifold vacuum tube support retainer to the valve cover and position the intake manifold vacuum tube aside. 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 8 ignition coil electrical connectors. 14. Position the air cleaner outlet pipe-to-TB adapter and install the 4 bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2370 ^ Tighten to 10 Nm (89 inch lbs.) 15. Connect the crankcase ventilation tube quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 16. Position the EVAP hose and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 17. Connect the EVAP hose position retainer to the intake manifold. 18. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. 19. Connect the heater coolant hose to the coolant bypass. 20. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction. 21. Install the generator. For additional information, refer to Alternator. 22. Install the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 23. Connect the battery ground cable. For additional information, refer to Battery. 24. Fill and bleed the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2371 Intake Manifold: Overhaul Intake Manifold Assembly Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2372 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2373 Disassembly 1. Remove the 4 bolts, the vibration damper and the throttle body (TB). 2. Remove the 4 bolts and the fuel rail. 3. Remove the fuel injector-to-fuel rail locking clips and separate the fuel injectors from the fuel rail. ^ Discard the 2 O-ring seals from each fuel injector. 4. Remove the charge motion control valve (CMCV) rod locking clips. 5. Remove the stud bolt, the 2 bolts and the CMCV. 6. Remove the 2 bolts and the positive crankcase ventilation (PCV) heater element. ^ Discard the O-ring seal. 7. 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. 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. 6. Assemble the fuel injectors onto the fuel rail and install the locking clips. 7. Install the fuel rail and fuel injector assembly onto the intake manifold. 8. Install the 4 fuel rail bolts. ^ Tighten to 10 Nm (89 inch lbs.) 9. NOTE: Lubricate the TB-to-intake manifold gasket with clean engine coolant prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2374 Install the TB, the vibration damper and tighten the bolts in 2 stages. ^ Stage 1: Tighten to 9 Nm (80 inch lbs.) ^ Stage 2: Tighten an additional 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Crankshaft Rear Seal Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2380 Special Tool(s) Material Removal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2381 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. 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. Installation 1. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the special tools, install a new crankshaft rear seal. 2. Using the special tools, install a new crankshaft rear oil slinger. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2382 3. Install the flexplate and tighten the 8 bolts in the sequence shown. ^ Tighten to 80 Nm (59 ft. lbs.) 4. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2383 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal With Retainer Plate Crankshaft Rear Seal with Retainer Plate Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2384 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2385 Material Removal 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the 8 bolts and the flexplate. 4. Using the special tools, remove the crankshaft oil slinger. ^ Discard the crankshaft oil slinger. 5. Using the special tools, remove the crankshaft rear seal. ^ Discard the crankshaft rear seal. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2386 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. 3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the special tools, install a new crankshaft rear seal. 5. Using the special tools, install a new crankshaft rear oil slinger. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2387 6. Install the flexplate and tighten the 8 bolts in the sequence shown. ^ Tighten to 80 Nm (59 ft. lbs.) 7. Install the oil pan. 8. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Seal Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2391 Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Release the cooling fan shroud position tab and rotate the shroud upward until the lower tab locks into position. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2392 5. Using the special tool, remove the crankshaft pulley. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2393 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 degrees. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.) ^ Stage 4: Tighten an additional 90 degrees. 6. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. 7. Release the cooling fan shroud position tab and rotate the shroud downward until the tab locks into position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2394 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2398 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. Position a new valve seal onto the valve stem. 2. Using the special tool, install the new valve seal. 3. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys. 4. Relieve the air pressure from the 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2399 6. Install the spark plug. For additional information, refer to Ignition System. 7. Depending on the valve being serviced, install the LH or RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2404 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2405 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the engine oil pressure (EOP) switch electrical connector. ^ To install, tighten to 18 Nm (13 ft. lbs.) 3. Remove the EOP switch. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 2413 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Discard the crankshaft pulley bolt. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing chain hydraulic tensioner bolts................................................................................................. ...................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2420 Timing Chain Tensioner: Service and Repair Timing Drive Components Special Tool(s) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2421 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 No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 5. 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 camshaft 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. NOTE: It may be necessary to push the valve down while compressing the spring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2422 Using the special tool, remove the 3 designated camshaft 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 camshaft 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. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2423 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2424 Remove the bolts, the RH timing chain tensioner and tensioner arm. 12. Remove the RH and LH timing chains and the crankshaft sprocket. ^ Remove the RH timing chain from the camshaft sprocket. ^ Remove the RH timing chain from the crankshaft sprocket. ^ Remove the LH timing chain from the camshaft sprocket. ^ Remove the LH timing chain and crankshaft sprocket. 13. NOTE: RH shown, LH similar. Remove the LH and RH timing chain guides. ^ Remove the bolts. ^ Remove both timing chain guides. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2425 14. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly. ^ Discard the VCT phaser sprocket bolt. 15. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly. ^ Discard the VCT phaser sprocket bolt. 16. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from sideloading when removing the cam unequally in height from the bearing towers. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2426 17. 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. 18. Remove the RH camshaft. 19. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from sideloading when removing the cam unequally in height from the bearing towers. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2427 20. 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. 21. Remove the LH camshaft. 22. 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 all of the remaining camshaft roller followers from the cylinder heads. Installation 1. Install the LH and RH camshafts. ^ Lubricate the camshaft and camshaft journals with clean engine oil prior to installation. 2. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations. ^ Lubricate the camshaft bearing caps with clean engine oil. ^ Position the 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2428 3. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar. Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight. 4. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket. NOTE: LH shown, RH similar. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages. ^ Stage 1: Tighten to 40 Nm (30 ft. lbs.) ^ Stage 2: Tighten an additional 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2429 5. 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. 8. Remove the tensioner from the vise. 9. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2430 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.) 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2431 13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2432 17. 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 VCT phaser sprocket with 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.) 19. Remove the retaining clip from the RH timing chain tensioner. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2433 20. As a post-check, verify correct alignment of all timing marks. 21. Install the crankshaft sensor ring on the crankshaft. 22. Using the special tool, install all of the camshaft roller followers. ^ Lubricate the camshaft roller followers with clean engine oil prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2434 23. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Front Fasteners Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2438 First pass: fasteners 1-15 .................................................................................................................... .................................................. 25 Nm (18 ft. lbs). Final pass: fasteners 6 & 7 ................................. ................................................................................................................................... 48 Nm (35 ft. lbs). Engine Front Cover Lower Fasteners First pass ............................................................................................................................................. .................................................. 20 Nm (15 ft. lbs). Final pass ............................................................ ............................................................................................................................................. Tighten 60° Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2439 Timing Cover: Service and Repair Engine Front Cover Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2440 Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2441 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2442 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2443 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2444 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 cooling fan shroud. For additional information, refer to Cooling System. 5. Remove the RH valve cover. 6. Remove the LH valve cover. 7. Rotate the tensioner clockwise and remove the accessory drive belt. 8. Remove the nut and the power steering pressure hose support bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2445 9. Remove the nut and the battery wiring harness and transmission cooler tube support brackets. 10. Remove the crankshaft pulley bolt and washer. - Discard the crankshaft pulley bolt. 11. Using the special tool, remove the crankshaft pulley. 12. Using the special tool, remove and discard the crankshaft front seal. 13. Remove the 3 bolts and the 3 accessory drive idler pulleys. 14. Remove the 4 bolts and the coolant pump pulley. 15. Remove the 3 bolts and the accessory drive belt tensioner. 16. Disconnect the RH camshaft position (CMP) sensor wiring harness retainer from the cylinder head. 17. Disconnect the A/C compressor electrical connector. 18. Disconnect the crankshaft position (CKP) sensor electrical connector. 19. Remove the bolt and the RH CMP sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2446 20. NOTE: LH shown, RH similar. Disconnect the radio ignition interference capacitor electrical connectors. 21. Remove the nut and the RH radio ignition interference capacitor. 22. Remove the nut and the LH radio ignition interference capacitor. 23. Remove the bolt and the LH CMP sensor. ^ Discard the O-ring seal. 24. Disconnect the wiring harness position retainer from the power steering pump stud bolt. 25. Disconnect the wiring harness position retainer and the engine oil pressure (EOP) switch electrical connector and position the wiring harness aside. 26. Remove the 2 bolts, the stud bolt and position the power steering pump assembly aside. 27. Remove the 4 front oil pan bolts. 28. Remove the bolts and the studs. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2447 29. Remove the engine front cover from the front cover to cylinder block dowel. 30. Remove the bolt and the CKP sensor. ^ Discard the O-ring seal. 31. 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. NOTE: Lubricate the O-ring with clean engine oil prior to installation. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2448 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. 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.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2449 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2450 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 degrees. 6. Position the power steering pump assembly and install the bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 7. Position the power steering pressure hose support bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.) 8. Position the transmission cooler tube support bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2451 9. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the RH CMP sensor and the bolt. ^ Tighten to 10 Nm (89 inch lbs.) 10. Connect the RH CMP sensor electrical connector. 11. Connect the wiring harness retainer from the cylinder head. 12. Connect the A/C compressor electrical connector. 13. Connect the CKP sensor electrical connector. 14. Install the LH radio ignition interference capacitor and the nut. ^ Tighten to 25 Nm (18 ft. lbs.) 15. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the LH CMP sensor and the bolt. ^ Tighten to 10 Nm (89 inch lbs.) 16. Connect the LH CMP sensor electrical connector. 17. Install the RH radio ignition interference capacitor and the nut. ^ Tighten to 25 Nm (18 ft. lbs.) 18. NOTE: LH shown, RH similar. Connect the radio ignition interference capacitor electrical connectors. 19. Connect the wiring harness position retainer to the power steering pump stud bolt. 20. Connect the wiring harness position retainer and the EOP switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2452 21. Install the accessory drive belt tensioner and the 3 bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 22. Install the coolant pump pulley and the 4 bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 23. Install the 3 accessory drive idler pulleys and the 3 bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 24. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil. 25. Using the special tools, install the crankshaft front seal into the engine front cover. 26. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2453 27. Use the special tool to install the crankshaft pulley. 28. Tighten the new crankshaft pulley bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 ft. lbs.) ^ Stage 2: Loosen 360 degrees. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.) ^ Stage 4: Tighten an additional 90 degrees. 29. Rotate the tensioner clockwise and install the accessory drive belt. 30. Install the RH valve cover. 31. Install the LH valve cover. 32. Install the cooling fan shroud. 33. Install the engine cooling fan. 34. Fill the crankcase with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2459 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2460 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 VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2461 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 (2007)) 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 (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the variable camshaft timing (VCT) oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1. Disconnect the battery ground cable. 2. Disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the air cleaner element. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 2476 Installation 1. CAUTION: The air cleaner element must be fully seated into 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 (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2484 Firing Order: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: Customer Interest Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 2497 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2503 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2504 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2505 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2506 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2507 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2508 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2509 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2510 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2511 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2512 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2513 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: All Technical Service Bulletins Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 2518 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2524 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2525 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2526 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2527 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2528 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2529 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2530 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2531 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2532 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2533 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2534 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2535 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2536 Spark Plug: Application and ID Spark plug ........................................................................................................................................... ....................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2537 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2538 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2539 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2540 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: - Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior to spark plug removal. - Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2544 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2545 leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 lash adjusters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant pump bolts .............................................................................................................................. ..................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2552 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.) 4. Rotate the belt tensioner clockwise and disconnect the accessory drive belt from the coolant pump pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2553 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 (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM BASE RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 20.6 quarts (19.5 liters) With aux rear heat ................................................ ....................................................................................................................... 23.2 quarts (22.0 liters) HEAVY DUTY TRAILER TOW RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 21.1 quarts (20.0 liters) With aux rear heat ................................................ ....................................................................................................................... 23.8 quarts (22.5 liters) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2562 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N .............................................................................................................................................. .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. WARNING: To avoid personal injury, do not unscrew the coolant pressure relief cap while the engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in personal injury. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise. When the pressure is released, remove the pressure relief cap. 2. Using hose clamp pliers, clamp the coolant return hose. 3. Using a suitable suction device, siphon the coolant from the degas bottle. 4. Remove the air cleaner element. For additional information, refer to Fuel Delivery and Air Induction. 5. Disconnect the degas bottle inlet coolant hose from the radiator. 6. Remove the clip and disconnect the coolant return hose quick connect coupling from the degas bottle. 7. Remove the 2 bolts and the degas bottle/lower air cleaner housing assembly. ^ To install, tighten to 15 Nm (11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 2566 8. To install, reverse the removal procedure. 9. Fill the degas bottle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 orientation. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Radiator Cooling Fan Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2589 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): Edge/MKX, Five Hundred/Freestyle/Montego, Fusion/Milan/MKZ, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (Negative Duty Cycle) 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: 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2590 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 (2007)) 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 (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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan Special Tool(s) Removal and Installation 1. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2597 2. Disconnect the cooling fan electronic clutch electrical connector. 3. Remove the nut and the cooling fan electronic clutch harness support bracket from the stud bolt. ^ To install, tighten to 13 Nm (10 ft. lbs.) 4. Release the cooling fan shroud position tab and rotate the shroud upwards until the lower tab locks into position. 5. Using the special tools, remove the cooling fan and clutch assembly. ^ To install, tighten to 55 Nm (41 ft. lbs.) ^ If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Cooling Fan Clutch. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams C1158 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2601 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 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2602 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2607 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2608 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2609 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Shroud Cooling Fan Shroud (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2613 Cooling Fan Shroud (Part 2) Cooling Fan Shroud (Part 3) Removal and Installation 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. Drain the engine cooling system. 4. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 5. Remove the nut and disconnect the electrical cables. ^ To install, tighten to 10 Nm (89 inch lbs.) 6. Disconnect the wiring harness retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2614 7. Disconnect the upper radiator hose from the radiator. 8. Disconnect the upper radiator hose position retainer from the cooling fan shroud. 9. Disconnect the electrical connector and the wiring harness position retainer. 10. If equipped, disconnect the wiring harness position retainer from the vacuum reservoir. 11. If equipped, disconnect the vacuum connectors and the electrical connector on the LH side of the cooling fan shroud and remove the vacuum canister. 12. Disconnect the wiring harness retainer from the RH side of the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2615 13. NOTE: LH shown, RH similar. Remove the 2 cooling fan shroud bolts and the wiring harness retainers. ^ To install, tighten to 10 Nm (89 inch lbs.) 14. Remove the 4 bolts and position the power distribution box (PDB) and support bracket aside. ^ NOTE: Hand start the 4 PDB support bracket bolts or damage to the radiator support can result. To install, tighten to 10 Nm (89 inch lbs.) 15. Disconnect the mass air flow (MAF) sensor electrical harness position retainer. 16. Disconnect the power steering fluid hose position retainers from the cooling shroud and radiator support. 17. Remove the bolt and position the power steering reservoir aside. ^ To install, tighten to 11 Nm (8 ft. lbs.) 18. Disconnect the degas bottle coolant inlet hose from the radiator. 19. Release the lower cooling fan shroud position tab and rotate the lower cooling fan shroud upwards until the lower tab locks into position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2616 20. Remove the clip and disconnect the lower radiator hose quick connect coupling from the radiator. 21. Remove the cooling fan shroud. 22. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2625 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2626 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2632 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2633 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2639 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2640 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2641 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2642 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2643 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2644 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2645 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2646 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2647 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2648 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2649 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems Misfire on Steady Cruise Spark Plug: All Technical Service Bulletins Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems Misfire on Steady Cruise > Page 2654 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2660 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2661 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2662 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2663 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2664 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2665 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2666 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2667 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2668 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2669 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 2670 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems Misfire on Steady Cruise > Page 2675 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2676 Heater Core: Description and Operation HEATER CORE The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the auxiliary climate control housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 8 plenum chamber screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2679 3. Release the plenum chamber clip and position the plenum chamber aside. 4. Remove 2 heater core fitting clips and the dash panel seal. 5. Remove the heater core tube bracket screw and the heater core tube bracket. 6. Remove the heater core bracket screw and the heater core bracket. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2680 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. 1. Remove the auxiliary heater core and evaporator core housing. 2. Release the clip and open the floorpan bracket. 3. Remove the heater core tube bracket screw and the heater core tube bracket. 4. Remove the 12 evaporator/heater core access cover screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2681 5. Remove the evaporator/heater core access cover. 6. Remove the heater core. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2682 Heater Core: Service and Repair Auxiliary Heater Core - Expedition EL, Navigator L AUXILIARY HEATER CORE - EXPEDITION EL, NAVIGATOR L Removal and Installation NOTE: - If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. - It is not necessary to install the new heater core tubes contained in the heater core service kit unless there is evidence of damage to the heater core tubes. New O-ring seals must be installed any time the heater core tubes are detached from the heater core. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the RH quarter trim panel. 4. Position a suitable drain pan and disconnect the 2 auxiliary heater outlet and inlet line quick disconnect fittings at the floorpan connections to allow any residual coolant to drain from the auxiliary heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2683 5. Remove the heater core door screw. 6. Remove the 2 auxiliary heater core tube fitting clips. 7. Disconnect the 2 auxiliary heater core tubes. 1 Position the auxiliary heater core partially out of the housing. 2 Disconnect the auxiliary heater core inlet tube. 3 Disconnect the auxiliary heater core outlet tube. Discard the O-ring seals. 8. Remove the auxiliary heater core. 9. NOTE: - Use only the O-ring seals contained in the auxiliary heater core service kit. - Verify that the heater core tube fittings are completely seated in the heater core before installing the heater core tube fitting clips. To install, reverse the removal procedure. 10. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2692 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 (2007)) 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 2693 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 (2007)) 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 (2007)) 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 2699 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 (2007)) 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 2700 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures Heater Hose: Procedures HEATER HOSE COUPLING Special Tool(s) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures > Page 2703 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 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures > Page 2704 Heater Hose: Removal and Replacement AUXILIARY HEATER OUTLET AND INLET LINE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures > Page 2705 Part 2 Removal NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. - The following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the RH fender splash shield. 5. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s). 6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition EL or Navigator L only 8. Remove the RH rear wheel and tire assembly. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures > Page 2706 9. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s). 10. Remove the muffler. 11. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 12. Remove the 3 muffler heat shield bolts and the muffler heat shield. 13. Remove the 2 exhaust hanger bolts and the exhaust hanger. 14. Remove the RH catalyst monitoring sensor. 15. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 16. Remove the 3 remaining auxiliary line bracket nuts and the line brackets. 17. 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). 18. Remove the auxiliary heater line(s) in 3 separate pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings. All vehicles 2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings. 3. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). 4. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 5. Tighten the middle auxiliary heater line fittings. 6. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 7. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts. 8. Install the RH catalyst monitoring sensor. 9. Install the exhaust hanger and the 2 exhaust hanger bolts. 10. Install the muffler heat shield and the 3 muffler heat shield bolts. 11. Install the muffler. 12. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 13. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 14. Install the front auxiliary line bracket and the front auxiliary line bracket and nut. - Tighten to 5 Nm (44 lb-in). 15. Install the RH front fender splash shield. 16. Install the RH front wheel. Expedition EL or Navigator L only 17. Install the RH rear wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Procedures > Page 2707 All vehicles 18. Install the spare tire. 19. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module Radiator: Service and Repair Cooling Module Cooling Module Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2712 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 cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2713 3. Recover the A/C system refrigerant. For additional information, refer to Heating and Air Conditioning. 4. Disconnect the battery ground cable. For additional information, refer to Battery. 5. Remove the RH and LH headlamp assemblies. 6. Remove the front fascia. 7. Remove the cooling fan shroud. 8. Remove the 2 hood latch assembly bolts. 9. Disconnect the cable position retainers and position the hood latch assembly aside. 10. Remove the pushpin and move the air deflector aside. 11. Remove the transmission cooler tube secondary latches. 12. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler hoses. 13. Remove the 2 condenser inlet fitting nuts and disconnect the 2 fittings. ^ Discard the O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2714 Expedition vehicles 14. Disconnect the horn electrical connector. Navigator vehicles 15. Disconnect the electrical connector and remove the bolt and the horn assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2715 All vehicles 16. Disconnect the ambient temperature sensor electrical connector. 17. Remove the 6 radiator support bolts and remove the cooling module from the vehicle. Installation All vehicles 1. Position the cooling module in the vehicle. 2. Install the 6 radiator support bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 3. Connect the ambient temperature sensor electrical connector. Navigator vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2716 4. Position the horn assembly and install the bolt and connect the electrical connector. ^ Tighten to 10 Nm (89 inch lbs.) Expedition vehicles 5. Connect the horn electrical connector. All vehicles 6. NOTE: Lubricate the new O-ring seals with PAG Refrigerant Compressor Oil prior to installation. Using new O-ring seals, connect the A/C fittings and install the 2 nuts. ^ Tighten to 8 Nm (71 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2717 7. Connect the transmission fluid cooler tubes and install the secondary latches. 8. Position the air deflector and install the pushpin. 9. Position the hood latch assembly and install the 2 hood latch assembly bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 10. Connect the hood latch cable position retainers. 11. Install the cooling fan shroud. 12. Install the front fascia. 13. Install the RH and LH headlamp assemblies. 14. Connect the battery ground cable. For additional information, refer to Battery. 15. Fill and bleed the engine cooling system. 16. Fill the transmission with fluid and verify correct operation. 17. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2718 Radiator: Service and Repair Radiator Radiator Radiator Removal and Installation All vehicles 1. 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2719 2. Remove the RH and LH headlamp assemblies. 3. Remove the cooling fan shroud. 4. Remove the 2 radiator-to-radiator support bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.) 5. Remove the 2 bolts and position the degas bottle aside. ^ To install, tighten to 15 Nm (11 ft. lbs.) Navigator vehicles 6. Disconnect the electrical connector and remove the bolt and the horn assembly. ^ To install, tighten to 10 Nm (89 inch lbs.) All vehicles 7. NOTE: LH shown, RH similar. Remove the 6 LH and RH air deflector-to-condenser core pin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2720 8. Disconnect the 2 transmission fluid cooler-to-radiator hoses. 9. NOTE: The cooling module must be positioned rearward to raise and detach the 4 condenser mounts from the radiator. Depress the retaining tabs on the 2 lower condenser mounting brackets and raise the condenser assembly until the 4 condenser mounting brackets detach from the radiator. 10. Remove the radiator. 11. To install, reverse the removal procedure. ^ Fill the transmission fluid level. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (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 (2007)) 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 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2729 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2730 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2731 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 (2007)) 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2735 Thermostat: Service and Repair Thermostat and Thermostat Housing Material Removal and Installation 1. Drain the engine cooling system. 2. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. ^ To install, tighten to 10 Nm (89 inch lbs.) 4. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat and Thermostat Housing Material Removal and Installation 1. Drain the engine cooling system. 2. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. ^ To install, tighten to 10 Nm (89 inch lbs.) 4. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant pump bolts .............................................................................................................................. ..................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2742 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.) 4. Rotate the belt tensioner clockwise and disconnect the accessory drive belt from the coolant pump pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2743 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 (2007)) 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. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Monitors/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 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2748 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 reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that 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 Typical Bank 1 Catalyst 2 HO2S Configuration Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2749 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 reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensor (HO2S) The HO2Ss provide the 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 (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts Discard the exhaust manifold nuts and studs. Studs ................................................................................................................................................... .................................................... 12 Nm (9 ft. lbs). Nuts ..................................................................... ................................................................................................................................. 25 Nm (18 ft. lbs). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2753 Exhaust Manifold: Testing and Inspection Exhaust Manifold Cleaning and Inspection Special Tool(s) 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces. 2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. Using the special tool (or a precision straight edge) and a feeler gauge, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 inch), install a new exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH Exhaust Manifold: Service and Repair Exhaust Manifold - LH Exhaust Manifold - LH Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2756 Removal 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 outlet tube. For additional information, refer to Fuel Delivery and Air Induction. 3. Remove the degas bottle. For additional information, refer to Cooling System. 4. 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. For additional information, refer to Air Bag Systems. Remove the bolt and disconnect the steering shaft and position aside. 5. Remove the 4 (2 LH and 2 RH) exhaust manifold-to-catalytic converter nuts. 6. Remove the 3 bolts and the exhaust manifold heat shield. Four wheel drive (4WD) vehicles 7. Remove the front driveshaft. All vehicles 8. Remove the 8 exhaust manifold nuts, studs and the exhaust manifold. ^ Discard the exhaust manifold nuts and studs. 9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2757 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. 10. Inspect the exhaust manifold. Installation All vehicles 1. Using new exhaust manifold gaskets and studs, position the 2 gaskets and exhaust manifold and install the 8 studs. ^ Tighten to 12 Nm (9 ft. lbs.) 2. Using new exhaust manifold nuts, install the 8 nuts. ^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown. 4WD vehicles 3. Install the front driveshaft. All vehicles 4. 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. For additional information, refer to Air Bag Systems. Connect the steering shaft and install the bolt. ^ To install, tighten to 30 Nm (22 ft. lbs.) 5. Install the 4 exhaust manifold-to-catalytic converter nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2758 6. Position the exhaust manifold heat shield and install the 3 bolts. ^ To install, tighten to 10 Nm (89 inch lbs.) 7. Install the degas bottle. 8. Install the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2759 Exhaust Manifold: Service and Repair Exhaust Manifold - RH Exhaust Manifold - RH Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2760 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the RH inner fenderwell. 3. Remove the RH engine support insulator. 4. Remove the 2 bolts and the exhaust manifold heat shield. 5. Remove the 8 exhaust manifold nuts, studs and the exhaust manifold. ^ Discard the exhaust manifold nuts and studs. 6. 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. 7. Inspect the exhaust manifold. Installation 1. Using new exhaust manifold gaskets and studs, position the 2 gaskets and exhaust manifold and install the 8 studs. ^ Tighten to 12 Nm (9 ft. lbs.) 2. Using new exhaust manifold nuts, install the 8 nuts. ^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown. 3. Position the exhaust manifold heat shield and install the 2 bolts. ^ Tighten to 10 Nm (89 inch lbs.) 4. Install the RH engine support insulator. For additional information, refer to Engine Support Insulators. 5. Install the RH inner fenderwell. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Exhaust System - Exploded View (Expedition and Navigator Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2764 Exhaust System - Exploded View (Expedition and Navigator Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2765 Exhaust System - Exploded View (Expedition EL and Navigator L Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2766 Exhaust System - Exploded View (Expedition EL and Navigator L Part 2) 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. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. NOTE: LH side shown, RH side similar. If equipped, remove the transfer case skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2767 All vehicles 3. Disconnect the heated oxygen and catalyst monitor sensors electrical connectors. 4. Using a suitable jack, support the transmission. 5. Remove the LH heat shield bolt and LH heat shield and evaporative emissions (EVAP) canister assembly bolt. 6. Remove the RH heat shield bolt. 7. Remove the transmission mount nuts. 8. Remove the 4 crossmember bolts and the crossmember. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2768 9. Loosen the exhaust and transmission mounting bracket cap bolt. Rear wheel drive (RWD) vehicles 10. Remove the 3 bolts and then slide off the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter. 4WD vehicles 11. NOTE: On 4WD vehicles, the exhaust and transmission mounting bracket will not slide off the exhaust Y-pipe dual catalytic converter until the exhaust Y-pipe dual catalytic converter is removed from the vehicle. NOTE: RH side shown, LH side similar. Remove the 4 bolts from the exhaust and transmission mounting bracket. All vehicles 12. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2769 13. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar. Remove and discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. 14. NOTE: Use caution removing the exhaust Y-pipe dual catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Remove the exhaust Y-pipe dual catalytic converter from the vehicle. 4WD vehicles 15. If necessary, remove the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter. All vehicles 16. NOTE: A new RH catalytic converter-to-LH catalytic converter clamp must be installed whenever the clamp is loosened. If necessary, loosen the RH catalytic converter-to-LH catalytic converter clamp. 17. If necessary, separate the RH catalytic converter from the LH catalytic converter. 18. If the RH catalytic converter-to-LH catalytic converter clamp is loosened, grind the spot weld and remove the RH catalytic converter-to-LH catalytic converter clamp. Clean the uneven surface area. Installation All vehicles 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. For additional information, refer to Exhaust System Alignment. NOTE: Clean the mating surfaces of the exhaust manifold outlet flare and the exhaust Y-pipe dual catalytic converter inlet flares. Also clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly. Make sure not to damage the exhaust manifold outlet flares, the exhaust Y-pipe-dual catalytic converter inlet flares or the studs. NOTE: Always install new fasteners and RH catalytic converter-to-LH catalytic converter clamp. 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.) 2. If necessary, position a new RH catalytic converter-to-LH catalytic converter clamp with the clamp bolt facing the front of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2770 3. If separated, install RH catalytic converter to the LH catalytic converter. 4WD vehicles 4. If removed, install the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter. All vehicles 5. NOTE: Use caution installing the Y-pipe dual catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Position the exhaust Y-pipe dual catalytic converter into the vehicle. 6. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar. Loosely install the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. 4WD vehicles 7. NOTE: RH side shown, LH side similar. Install the 4 exhaust and transmission mounting bracket-to-transmission bolts. ^ Tighten to 90 Nm (66 ft. lbs.) RWD vehicles 8. Slide on the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter and install the 3 exhaust and transmission mounting bracket-to-transmission bolts. ^ Tighten to 90 Nm (66 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2771 All vehicles 9. Install the 4 crossmember bolts and the crossmember. ^ Tighten to 90 Nm (66 ft. lbs.) 10. Install the exhaust and transmission mounting bracket nuts. ^ Tighten to 103 Nm (76 ft. lbs.) 11. Install the RH heat shield bolt. ^ Tighten to 20 Nm (15 ft. lbs.) 12. Install the LH heat shield bolt and LH heat shield and evaporative emissions (EVAP) canister assembly bolt. ^ Tighten to 20 Nm (15 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2772 13. Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts. 14. Connect the heated oxygen and catalyst monitor sensor electrical connectors. 15. Align the exhaust system. 4WD vehicles 16. NOTE: LH side shown, RH side similar. If equipped, install the transfer case skid plate. ^ Tighten to 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler and Tailpipe Exhaust System - Exploded View (Expedition and Navigator Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2776 Exhaust System - Exploded View (Expedition and Navigator Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2777 Exhaust System - Exploded View (Expedition EL and Navigator L Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2778 Exhaust System - Exploded View (Expedition EL and Navigator L Part 2) Removal 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. NOTE: LH side shown, RH side similar. If equipped, remove the transfer case skid plate. 3. Loosen the tailpipe or resonator-to-muffler assembly clamp. 4. Remove the isolator and bracket assembly bolts and remove: ^ the tailpipe for Expedition models. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2779 ^ the resonator for Navigator models. 5. Using a suitable jack stand, support the muffler. 6. Remove and discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and flag nuts. 7. CAUTION: Make sure not to make contact with the axle boots while routing the muffler assembly outlet over the rear axle or damage to the boots may result. Detach the isolators from the muffler assembly and remove from the vehicle Installation 1. NOTE: Clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly. NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary. Install the muffler assembly into the vehicle and attach the isolators. 2. NOTE: Always install new fasteners. Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and flag nuts. 3. Install the tailpipe for Expedition models or the resonator for Navigator models and install the isolator and bracket assembly bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 4. Tighten the tailpipe or resonator-to-muffler assembly clamp. ^ Tighten to 48 Nm (35 ft. lbs.) 5. Align the exhaust system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2780 6. NOTE: LH side shown, RH side similar. If equipped, install the transfer case skid plate. ^ Tighten to 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Programmable Module Installation Body Control Module: Service and Repair Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the Original Module is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation Using the Integrated Diagnostic System IDS) When the Original Module is NOT Available NOTE: Following module installation, some modules require a separate learning procedure carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press check mark. 8. If the data is not available, the IDS displays screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Programmable Module Installation > Page 2789 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. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (TP) sensor, 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 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 (2007)) 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 2793 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 convened 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 (2007)) 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 2794 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 (2007)) 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 2795 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. 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 (2007)) 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 2796 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 (2007)) 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 2797 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 4% - Out of range, limp home default position. - Greater than or equal to 4% 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 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% 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 (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 2806 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 2811 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 2817 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 2822 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2823 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2826 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2827 orientation. 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 (2007)) 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 2828 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2829 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2830 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2831 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2832 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2833 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2834 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2835 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2836 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2837 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2838 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2839 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2840 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2841 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2842 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2843 Engine Control Module: Connector Views C175B (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2844 C175B (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2845 C175E (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2846 C175E (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the battery ground cable. 3. Disconnect the 2 PCM electrical connectors. 4. Remove the 2 bolts and the ground cable. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the PCM. 6. To install, reverse the removal procedure. Installation 1. Install the PCM. 2. Position the ground cable and install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Connect the battery ground cable. 5. NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON. The warning indicator will remain on until PCM configuration is restored - Clear all restraints control module (RCM) continuous diagnostic trouble codes (DTCs) after Programmable Module Installation procedure has Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) > Page 2849 been completed on the PCM. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Powertrain Control Module (PCM) > Page 2850 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. 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 needs 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 using a scan 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. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2854 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2855 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2856 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2861 Fuel Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2862 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2863 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2867 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2868 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2869 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2874 Ignition Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2875 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2876 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2882 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2883 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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2887 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2888 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 (2007)) 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 2889 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2890 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 2899 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 2905 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2906 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2909 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2910 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2911 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2918 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2919 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2920 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2924 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2925 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2926 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 (2007)) 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) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2930 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2931 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2935 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2936 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2937 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2938 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR 106L (28 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2939 106L (28 Gallon) Fuel Tank (Part 2) 125L (33 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2940 125L (33 Gallon) Fuel Tank (Part 2) Removal and Installation All fuel tanks 1. Remove the fuel tank. 106 L (28 gal.) fuel tank 2. Disconnect the supply and return fuel tubes quick connect couplings from the fuel filter. All fuel tanks 3. Remove the fuel tank heat shield retainer(s) and remove the fuel tank heat shield. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 5. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 6. NOTE: For the 106 L (28 gal.) fuel tank the fuel tank pressure sensor and vapor tube assembly and fresh air tube are serviced as an assembly. Remove the fuel tank pressure sensor and vapor tube assembly with the fresh air tube from the fuel tank. 125 L (33 gal.) fuel tank 7. Remove the fuel tank pressure sensor and vapor tube assembly from the fuel tank. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2941 - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2945 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2946 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 fuel, spark, and air flow. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2947 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. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2953 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2954 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2955 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2966 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2967 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2968 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2969 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2970 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2973 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2974 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2975 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2976 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 (2007)) 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 (2007)) 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 2979 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2980 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 (2007)) 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 2981 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. 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. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2986 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 2990 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2994 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 2997 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 2998 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3003 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3004 orientation. 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 (2007)) 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 3005 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3006 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3007 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3008 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3009 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3010 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3011 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3012 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3013 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3014 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3015 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3016 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3017 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3018 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3019 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 that is generated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3024 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 3029 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3034 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3035 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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3039 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3040 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 (2007)) 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 3041 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3042 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3047 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3054 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3055 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3056 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 (2007)) 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 3057 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 (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3061 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3064 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3065 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3075 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3081 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3082 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3085 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3086 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3087 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3091 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3092 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3093 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3099 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3105 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3106 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 (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3107 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 1. Disconnect the battery ground cable. 2. Disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the air cleaner element. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3119 Installation 1. CAUTION: The air cleaner element must be fully seated into 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 (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3127 Firing Order: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems Misfire on Steady Cruise Spark Plug: Customer Interest Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems Misfire on Steady Cruise > Page 3140 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3146 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3147 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3148 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3149 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3150 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3151 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3152 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3153 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3154 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3155 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3156 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: All Technical Service Bulletins Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 3161 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3167 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3168 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3169 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3170 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3171 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3172 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3173 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3174 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3175 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3176 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 3177 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3178 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3179 Spark Plug: Application and ID Spark plug ........................................................................................................................................... ....................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3180 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3181 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3182 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 3183 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: - Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior to spark plug removal. - Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - 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 (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3187 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3188 leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 lash adjusters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3196 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3197 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3201 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3202 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3203 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3204 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3208 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3209 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 fuel, spark, and air flow. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3210 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. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation Body Control Module: Service and Repair Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the Original Module is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation Using the Integrated Diagnostic System IDS) When the Original Module is NOT Available NOTE: Following module installation, some modules require a separate learning procedure carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press check mark. 8. If the data is not available, the IDS displays screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation > Page 3216 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. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 3220 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 3223 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 (DTC) is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3232 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3238 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3239 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 3242 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3243 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3244 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3251 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3252 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3253 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 orientation. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 C251 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 3280 C1368 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 3281 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 degree 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 (2007)) 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 (TP) sensor, 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 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3285 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 convened 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3286 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3287 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. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3288 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3289 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 4% - Out of range, limp home default position. - Greater than or equal to 4% 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 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 3298 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3303 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 3309 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3314 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3315 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 orientation. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 Engine Control Module: Connector Views C175B (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 C175B (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 C175E (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 C175E (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the battery ground cable. 3. Disconnect the 2 PCM electrical connectors. 4. Remove the 2 bolts and the ground cable. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the PCM. 6. To install, reverse the removal procedure. Installation 1. Install the PCM. 2. Position the ground cable and install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Connect the battery ground cable. 5. NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON. The warning indicator will remain on until PCM configuration is restored - Clear all restraints control module (RCM) continuous diagnostic trouble codes (DTCs) after Programmable Module Installation procedure has Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3341 been completed on the PCM. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3342 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. 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 needs 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 using a scan 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. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3346 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3347 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3348 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 (2007)) 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) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3352 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3353 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3357 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3358 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3359 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3360 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR 106L (28 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3361 106L (28 Gallon) Fuel Tank (Part 2) 125L (33 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3362 125L (33 Gallon) Fuel Tank (Part 2) Removal and Installation All fuel tanks 1. Remove the fuel tank. 106 L (28 gal.) fuel tank 2. Disconnect the supply and return fuel tubes quick connect couplings from the fuel filter. All fuel tanks 3. Remove the fuel tank heat shield retainer(s) and remove the fuel tank heat shield. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 5. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 6. NOTE: For the 106 L (28 gal.) fuel tank the fuel tank pressure sensor and vapor tube assembly and fresh air tube are serviced as an assembly. Remove the fuel tank pressure sensor and vapor tube assembly with the fresh air tube from the fuel tank. 125 L (33 gal.) fuel tank 7. Remove the fuel tank pressure sensor and vapor tube assembly from the fuel tank. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3363 - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/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 (2007)) 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 (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 orientation. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 14-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 14-3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 14-4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 14-5 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3393 Information Bus: Description and Operation COMMUNICATIONS NETWORK Vehicle communication utilizes both medium and high speed controller area network (CAN) communications. CAN is used for many modules to communicate with each other on a common network. CAN in-vehicle networking, is a method for transferring data among distributed electronic modules via a serial data bus. Without serial networking, intermodule communication requires dedicated, point to point wiring resulting in bulky, expensive, complex, and difficult to install wiring harnesses. Applying a serial data network reduces the number of wires combining the signals on a single network. Information is sent to the individual control modules that control each function. The vehicle has 2 module communication networks: - Medium speed (MS) CAN - High speed (HS) CAN Both networks are connected to the data link connector (DLC). This makes diagnosis and testing of these systems easier by allowing one scan tool to be able to diagnose and control any module on both networks from one connector. The DLC can be found under the instrument panel between the steering column and the audio unit. MS-CAN Network Operation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3394 Network Topology The MS-CAN network communicates using bussed messages. The MS-CAN has an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The MS-CAN is a medium speed communication network used for the following modules: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3395 - SJB - Audio unit - Instrument cluster - DSM (if equipped) - DVD player (if equipped) - Electronic manual temperature control module (if equipped) - EATC module (if equipped) - SDARS module (if equipped) - Parking aid module (if equipped) - Power liftgate module (if equipped) - Auxiliary audio module (if equipped) - THX(R) amplifier (if equipped) - Power running board module (if equipped) - Climate controlled seat module (if equipped) HS-CAN Network Operation The HS-CAN network communicates using bussed messages. The HS-CAN network uses an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The HS-CAN is a high speed communication network used for the following modules: PCM - RCM - ABS module - Instrument cluster - TCM (if equipped) - 4WD control module (if equipped) - Air suspension module (if equipped) Network Termination The CAN network uses a network termination circuit to improve communication reliability. The network termination of the CAN bus takes place inside the termination modules by termination resistors. Termination modules are located at either end of the bus network. As network messages are broadcast in the form of voltage signals, the network voltage signals are stabilized by the termination resistors. Each termination module has a 120 ohm resistor across the positive and negative bus connection in the termination module. With 2 termination modules on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or total resistance is 60 ohms. Network termination improves bus message reliability by: stabilizing bus voltage. - eliminating electrical interference. Gateway Module The instrument cluster is the gateway module, translating HS-CAN to MS-CAN and vice versa. This information allows a message to be distributed throughout both networks. The instrument cluster is the only module on this vehicle that has this ability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 7 (40A) (no communication with power running board module) - 8 (40A) (no communication with climate controlled seat module) - 35 (20A) (no communication with 4WD control module) - 36 (10A) (no communication with PCM) - 37 (15A) (no communication with TCM) - 43 (20A) (no communication with 4WD control module) - 45 (30A) (no communication with DSM) - 47 (30A) (no communication with air suspension module) - 65 (10A) (no communication with air suspension module) - 73 (5A) (no communication with TCM) - 76 (20A) (no communication with PCM) - 77 (10A) (no communication with ABS module) - Smart junction box (SJB) fuse(s): 2 (15A) (no communication with DSM) - 3 (15A) (no communication with satellite radio receiver, auxiliary audio module, DVD) - 5 (10A) (no communication with SJB) - 14 (10A) (no communication with power liftgate module) - 15 (10A) (no communication with electronic manual temperature control module, EATC module) - 20 (15A) (no power to scan tool) - 26 (20A) (no communication with SJB) - 28 (5A) (no communication with audio unit) - 29 (5A) (no communication with instrument cluster) - 32 (10A) (no communication with RCM) - 35 (10A) (no communication with parking aid module) - 37 (10A) (no communication with Electronic manual temperature control module, EATC module) - 38 (20A) (no communication with THX(R) amplifier) - 39 (20A) (no communication with audio unit) - 40 (20A) (no communication with THX(R) amplifier) - Data link connector (DLC) - Wiring harness - Circuitry 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the DLC. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - GO to Pinpoint Test W, to diagnose no power to the scan tool. See: Pinpoint Tests/Test W: No Power To The Scan Tool 5. NOTE: During the network test, the scan tool will first attempt to communicate with the PCM, after establishing communication with the PCM, the scan tool will then attempt to communicate with all other modules on the vehicle. Carry out the network test. If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step 6. - If the network test fails, GO to Symptom Chart to identify the module not communicating. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3398 6. If the DTCs retrieved are related to the concern, go to the Communication Network Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION Vehicle communication utilizes both medium and high speed controller area network (CAN) communications. CAN is a method for transferring data among distributed electronic modules via a serial data bus. The vehicle is equipped with 2 module communication networks: - Medium speed (MS) CAN - High speed (HS) CAN MS-CAN The MS-CAN is a medium speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The MS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN network may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN network operates at a maximum data transfer speed of 125 Kbps for bus messages and designed for general information transfer. The network will remain operational, but at a degraded level when certain circuit faults are present. The HS-CAN network may remain operational with only one termination resistor present. The following modules are on the MS-CAN network: Smart junction box (SJB) - Instrument cluster - Audio unit - THX(R) amplifier (if equipped) - Satellite radio receiver (if equipped) - Power running board module (if equipped) - Parking aid module (if equipped) - Power liftgate module (if equipped) - Electronic manual temperature control module (if equipped) - Electronic automatic temperature control (EATC) module (if equipped) - Driver seat module (DSM) (if equipped) - Climate controlled seat module (if equipped) - Auxiliary audio module (if equipped) - Digital versatile disc (DVD) player (if equipped) MS-CAN Network Communication Fault Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3399 The fault chart describes the specific MS-CAN network failures and their resulting symptom: HS-CAN The HS-CAN is a high speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The HS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The HS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The HS-CAN network operates at a maximum data transfer speed of 500 Kbps and is designed for real time information transfer and control. The network will remain operational, but at a degraded level when certain circuit faults are present. The HS-CAN network may remain operational with only one termination resistor present. The following modules are on the HS-CAN network: Powertrain control module (PCM) - Anti-lock brake system (ABS) module - Restraints control module (RCM) - Instrument cluster - Transmission control module (TCM) - Four wheel drive (4WD) control module (if equipped) - Air suspension module (if equipped) HS-CAN Network Communication Fault Chart The fault chart describes the specific HS-CAN network failures and their resulting symptom: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3400 CAN Network Module Communication Message Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3401 CAN Network Module Communication Message Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3402 CAN Network Module Communication Message Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3403 CAN Network Module Communication Message Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3404 CAN Network Module Communication Message Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3405 CAN Network Module Communication Message Chart (Part 6) The chart describes the specific CAN network messages broadcast by each module, and the module(s) that receive the message: Inspection and Verification INSPECTION AND VERIFICATION This provides step-by-step module configuration procedures. Carry out the programmable module installation (PMI) procedure when another Vehicle System directs to carry out configuration or when DTCs from the list are present. See: Body Control Module/Service and Repair Principles of Operation PRINCIPLES OF OPERATION Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in improper operation and/or any of the following DTCs setting: - B2477 and/or B2141 - sets when a body/chassis module is not configured. - B2900 - sets when there is a VIN mismatch between the module with the B2900 and the PCM. Either the PCM or the body module stored VIN may be incorrect. - P0602, P0605 and/or P1639 - sets when the powertrain control module (PCM) vehicle identification (VID) block is not configured or is configured incorrectly. - U0300 and/or U0301 - sets when the configuration between 2 or more modules do not match. - U2050 and/or U2051 - sets when a valid strategy/calibration is not present. The following are the 3 different methods of configuration: - Programmable module installation (PMI) - Module reprogramming (flashing) - Programmable parameters Some modules do not support all 3 methods. Definition of Terms The following are definitions of configuration terms: Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a new module. Data used for the PMI process is automatically downloaded from the original module and stored when a scan tool session is started. If this data cannot be retrieved from the module being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter values that need to be manually selected. Some modules are reprogrammed during PMI when a strategy/calibration update is available. NOTE: A module must be able to communicate with the scan tool in order to carry out PMI. It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. To carry out PMI, refer to Programmable Module Installation. See: Body Control Module/Service and Repair Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3406 NOTE: Module reprogramming should be limited to circumstances where a published Technical Service Bulletin (TSB) procedure recommends doing so. - A module cannot communicate with other modules on the communication network while being reprogrammed. Clear any network communication DTCs which may have been set in other modules during reprogramming. Programmable Parameters Programmable parameters are customer preference items that may be modified by the dealer via scan tool or in some cases modified by the customer following a procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a module, only a few of these options are programmable parameters. Adaptive Learning and Calibration Some modules require a separate learning procedure be carried out if replaced as part of a repair procedure. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The PCM VID block commonly stores powertrain configuration items such as VIN, tire size, axle ratio, and whether or not the vehicle is equipped with speed control. As-Built Data As-Built data is a VIN specific module configuration record. During vehicle build, the configuration from all modules is downloaded and stored in the As-Built database. As Built data will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. Body/Chassis Module Addresses For As-Built Entry The chart lists body/chassis module As-Built data addresses: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3407 Module Configuration And Parameter Index (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3408 Module Configuration And Parameter Index (Part 2) Module Configuration And Parameter Index (Part 3) The chart describes specific module programming information: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3409 Information Bus: Diagnostic Trouble Code Descriptions U0001-U0114 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3410 U0121-U0155 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3411 U0155-U0208 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3412 U0230-U2023 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3413 U2023-U2473 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3414 Information Bus: Diagnostic Trouble Code Tests and Associated Procedures B2477-B2900 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3415 P0602-P1639 / U0300-U2050 U2051 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3416 Information Bus: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3417 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3418 Information Bus: Testing and Inspection Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 7 (40A) (no communication with power running board module) - 8 (40A) (no communication with climate controlled seat module) - 35 (20A) (no communication with 4WD control module) - 36 (10A) (no communication with PCM) - 37 (15A) (no communication with TCM) - 43 (20A) (no communication with 4WD control module) - 45 (30A) (no communication with DSM) - 47 (30A) (no communication with air suspension module) - 65 (10A) (no communication with air suspension module) - 73 (5A) (no communication with TCM) - 76 (20A) (no communication with PCM) - 77 (10A) (no communication with ABS module) - Smart junction box (SJB) fuse(s): 2 (15A) (no communication with DSM) - 3 (15A) (no communication with satellite radio receiver, auxiliary audio module, DVD) - 5 (10A) (no communication with SJB) - 14 (10A) (no communication with power liftgate module) - 15 (10A) (no communication with electronic manual temperature control module, EATC module) - 20 (15A) (no power to scan tool) - 26 (20A) (no communication with SJB) - 28 (5A) (no communication with audio unit) - 29 (5A) (no communication with instrument cluster) - 32 (10A) (no communication with RCM) - 35 (10A) (no communication with parking aid module) - 37 (10A) (no communication with Electronic manual temperature control module, EATC module) - 38 (20A) (no communication with THX(R) amplifier) - 39 (20A) (no communication with audio unit) - 40 (20A) (no communication with THX(R) amplifier) - Data link connector (DLC) - Wiring harness - Circuitry 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the DLC. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - GO to Pinpoint Test W, to diagnose no power to the scan tool. See: Pinpoint Tests/Test W: No Power To The Scan Tool 5. NOTE: During the network test, the scan tool will first attempt to communicate with the PCM, after establishing communication with the PCM, the scan tool will then attempt to communicate with all other modules on the vehicle. Carry out the network test. If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step 6. - If the network test fails, GO to Symptom Chart to identify the module not communicating. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3419 6. If the DTCs retrieved are related to the concern, go to the Communication Network Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION Vehicle communication utilizes both medium and high speed controller area network (CAN) communications. CAN is a method for transferring data among distributed electronic modules via a serial data bus. The vehicle is equipped with 2 module communication networks: - Medium speed (MS) CAN - High speed (HS) CAN MS-CAN The MS-CAN is a medium speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The MS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN network may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN network operates at a maximum data transfer speed of 125 Kbps for bus messages and designed for general information transfer. The network will remain operational, but at a degraded level when certain circuit faults are present. The HS-CAN network may remain operational with only one termination resistor present. The following modules are on the MS-CAN network: Smart junction box (SJB) - Instrument cluster - Audio unit - THX(R) amplifier (if equipped) - Satellite radio receiver (if equipped) - Power running board module (if equipped) - Parking aid module (if equipped) - Power liftgate module (if equipped) - Electronic manual temperature control module (if equipped) - Electronic automatic temperature control (EATC) module (if equipped) - Driver seat module (DSM) (if equipped) - Climate controlled seat module (if equipped) - Auxiliary audio module (if equipped) - Digital versatile disc (DVD) player (if equipped) MS-CAN Network Communication Fault Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3420 The fault chart describes the specific MS-CAN network failures and their resulting symptom: HS-CAN The HS-CAN is a high speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The HS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The HS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The HS-CAN network operates at a maximum data transfer speed of 500 Kbps and is designed for real time information transfer and control. The network will remain operational, but at a degraded level when certain circuit faults are present. The HS-CAN network may remain operational with only one termination resistor present. The following modules are on the HS-CAN network: Powertrain control module (PCM) - Anti-lock brake system (ABS) module - Restraints control module (RCM) - Instrument cluster - Transmission control module (TCM) - Four wheel drive (4WD) control module (if equipped) - Air suspension module (if equipped) HS-CAN Network Communication Fault Chart The fault chart describes the specific HS-CAN network failures and their resulting symptom: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3421 CAN Network Module Communication Message Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3422 CAN Network Module Communication Message Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3423 CAN Network Module Communication Message Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3424 CAN Network Module Communication Message Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3425 CAN Network Module Communication Message Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3426 CAN Network Module Communication Message Chart (Part 6) The chart describes the specific CAN network messages broadcast by each module, and the module(s) that receive the message: Inspection and Verification INSPECTION AND VERIFICATION This provides step-by-step module configuration procedures. Carry out the programmable module installation (PMI) procedure when another Vehicle System directs to carry out configuration or when DTCs from the list are present. See: Body Control Module/Service and Repair Principles of Operation PRINCIPLES OF OPERATION Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in improper operation and/or any of the following DTCs setting: - B2477 and/or B2141 - sets when a body/chassis module is not configured. - B2900 - sets when there is a VIN mismatch between the module with the B2900 and the PCM. Either the PCM or the body module stored VIN may be incorrect. - P0602, P0605 and/or P1639 - sets when the powertrain control module (PCM) vehicle identification (VID) block is not configured or is configured incorrectly. - U0300 and/or U0301 - sets when the configuration between 2 or more modules do not match. - U2050 and/or U2051 - sets when a valid strategy/calibration is not present. The following are the 3 different methods of configuration: - Programmable module installation (PMI) - Module reprogramming (flashing) - Programmable parameters Some modules do not support all 3 methods. Definition of Terms The following are definitions of configuration terms: Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a new module. Data used for the PMI process is automatically downloaded from the original module and stored when a scan tool session is started. If this data cannot be retrieved from the module being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter values that need to be manually selected. Some modules are reprogrammed during PMI when a strategy/calibration update is available. NOTE: A module must be able to communicate with the scan tool in order to carry out PMI. It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. To carry out PMI, refer to Programmable Module Installation. See: Body Control Module/Service and Repair Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3427 NOTE: Module reprogramming should be limited to circumstances where a published Technical Service Bulletin (TSB) procedure recommends doing so. - A module cannot communicate with other modules on the communication network while being reprogrammed. Clear any network communication DTCs which may have been set in other modules during reprogramming. Programmable Parameters Programmable parameters are customer preference items that may be modified by the dealer via scan tool or in some cases modified by the customer following a procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a module, only a few of these options are programmable parameters. Adaptive Learning and Calibration Some modules require a separate learning procedure be carried out if replaced as part of a repair procedure. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The PCM VID block commonly stores powertrain configuration items such as VIN, tire size, axle ratio, and whether or not the vehicle is equipped with speed control. As-Built Data As-Built data is a VIN specific module configuration record. During vehicle build, the configuration from all modules is downloaded and stored in the As-Built database. As Built data will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. Body/Chassis Module Addresses For As-Built Entry The chart lists body/chassis module As-Built data addresses: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3428 Module Configuration And Parameter Index (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3429 Module Configuration And Parameter Index (Part 2) Module Configuration And Parameter Index (Part 3) The chart describes specific module programming information: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3430 U0001-U0114 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3431 U0121-U0155 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3432 U0155-U0208 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3433 U0230-U2023 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3434 U2023-U2473 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3435 B2477-B2900 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3436 P0602-P1639 / U0300-U2050 U2051 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3437 Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3438 Symptom Chart (Part 2) Test A: The Powertrain Control Module (PCM) Does Not Respond To The Scan Tool PINPOINT TEST A: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3439 A1-A2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3440 A2-A3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3441 A4 Normal Operation The PCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the PCM. The PCM shares the HS-CAN network with the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the air suspension module (if equipped) and the instrument cluster. DTC U0100 - sets in a module which had attempted to communicate with the PCM and failed. Possible Causes - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - PCM Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool PINPOINT TEST B: THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND TO THE SCAN TOOL B1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3442 B1-B3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3443 B3-B4 Normal Operation The TCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the TCM. The TCM shares the HS-CAN network with the powertrain control module (PCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the air suspension module (if equipped) and the instrument cluster. Voltage for the TCM is provided by circuits CBB73 (WH/BN) and SBB37 (GY/RD). Circuit GD113 (BK/YE) provides ground. DTC U0101 - sets in a module which had attempted to communicate with the TCM and failed. Possible Causes - Fuse - Circuit CBB73 (WH/BN) open - Circuit GD113 (BK/YE) open - Circuit SBB37 (GY/RD) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - TCM Test C: The Anti-Lock Brake System (ABS) Module Does Not Respond To The Scan Tool PINPOINT TEST C: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3444 C1-C2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3445 C3-C4 Normal Operation The ABS module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the ABS module. The ABS module shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM), the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the air suspension module (if equipped) and the instrument cluster. Voltage for the ABS module is provided by circuit CBB77 (WH), and ground is provided by circuit GD120 (BK/GN). DTC U0121 - sets in a module which had attempted to communicate with the ABS control module and failed. Possible Causes - Fuse - Circuit CBB77 (WH) open - Circuit GD120 (BK/GN) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - ABS module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3446 Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool PINPOINT TEST D: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO THE SCAN TOOL D1-D2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3447 D2-D4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3448 D4-D5 Normal Operation The RCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the RCM. The RCM shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the four wheel drive (4WD) control module (if equipped), the air suspension module (if equipped) and the instrument cluster. Voltage for the RCM is provided by circuit CBP32 (GN/VT), and the RCM is case grounded. DTC U0151 - sets in a module which had attempted to communicate with the RCM and failed. Possible Causes - Fuse - Circuit CBP32 (GN/VT) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - Case ground open - RCM Test E: The Four Wheel Drive (4WD) Control Module Does Not Respond To The Scan Tool PINPOINT TEST E: THE FOUR WHEEL DRIVE 4WD) CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3449 E1-E2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3450 E3-E4 Normal Operation The 4WD control module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the 4WD control module. The 4WD control module shares the HS-CAN with powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the air suspension module if equipped) and the instrument cluster. Voltage is supplied by circuits CBP35 (YE/GY), SBB35 BU/RD) and SBB43 (BU/RD). Ground is supplied by circuits GD123 (BK/GY) and GD133 (BK). DTC U0102 or DTC U0114 - sets in a module which had attempted to communicate with the 4WD control module and failed. Possible Causes - Fuse - Circuit CBP35 (YE/GY) open - Circuit GD123 (BK/GY) open - Circuit GD133 (BK) open - Circuit SBB35 (BU/RD) open - Circuit SBB43 (BU/RD) open Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3451 - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - 4WD control module Test F: The Air Suspension Module Does Not Respond To The Scan Tool PINPOINT TEST F: THE AIR SUSPENSION MODULE DOES NOT RESPOND TO THE SCAN TOOL F1-F2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3452 F3-F4 Normal Operation The air suspension module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the air suspension module. The air suspension module shares the HS-CAN with powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped) and the instrument cluster. Voltage for the air suspension module is provided by circuits CBB65 (WH/OG) and SBB47 (WH/RD). Circuits GD120 (BK/GN) and GD133 (BK) provide ground. DTC U0122 - sets in a module which had attempted to communicate with the air suspension module and failed. Possible Causes - Fuse - Circuit CBB65 (WH/OG) open - Circuit SBB47 (WH/RD) open - Circuit GD120 (BK/GN) open - Circuit GD133 (BK) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3453 - Air suspension module Test G: The Instrument Cluster Does Not Respond To The Scan Tool PINPOINT TEST G: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE SCAN TOOL G1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3454 G1-G3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3455 G4-G5 Normal Operation The instrument cluster communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN network connection to the instrument cluster and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN network connection to the instrument cluster. The instrument cluster shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped) and the air suspension module (if equipped). The instrument cluster shares the MS-CAN network with the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the climate controlled seat module (if equipped), the power liftgate module (if equipped), the parking aid module (if equipped), the power running board module (if equipped), the auxiliary audio module and the digital versatile disc (DVD) player. Voltage for the instrument cluster is provided by circuits CBP29 (WH/VT) and SBP26 (YE/RD). Circuit GD133 (BK) provides ground. DTC U0155 - sets in a module which had attempted to communicate with the instrument cluster and failed. Possible Causes - Fuse - Circuit CBP29 (WH/VT) open Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3456 - Circuit GD133 (BK) open - Circuit SBP26 (YE/RD) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - Instrument cluster Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool PINPOINT TEST H: THE SMART JUNCTION BOX (SJB) DOES NOT RESPOND TO THE SCAN TOOL H1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3457 H1-H3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3458 H3-H4 Normal Operation The SJB communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SJB. The SJB shares the MS-CAN network with the instrument cluster, the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the climate controlled seat module (if equipped), the power liftgate module (if equipped), the parking aid module (if equipped), the power running board module (if equipped), the auxiliary audio module (if equipped) and the digital versatile disc (DVD) player (if equipped). Voltage for the SJB is provided by circuit CDC33 (VT/GN). Circuit GD133 (BK) provides ground. DTC U0140 - sets in a module which had attempted to communicate with the SJB and failed. Possible Causes - Fuse - Circuit CDC33 (VT/GN) open - Circuit GD133 (BK) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - SJB Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3459 Test I: The Electronic Manual Temperature Control Module Does Not Respond To The Scan Tool PINPOINT TEST I: THE ELECTRONIC MANUAL TEMPERATURE CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL I1-I2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3460 I2-I3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3461 I3-I4 Normal Operation The electronic manual temperature control module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the electronic manual temperature control module. The electronic manual temperature control module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the auxiliary audio module, the digital versatile disc (DVD) player, the driver seat module (DSM) (if equipped), the power running board module, the parking aid module (if equipped), the power liftgate module and the climate controlled seat module (if equipped). Voltage for the electronic manual temperature control module is provided by circuits CBP37 (WH) and SBP15 (WH/RD). Circuit GD133 (BK) provides ground. Possible Causes - Fuse - Circuit CBP37 (WH) open - Circuit GD133 (BK) open - Circuit SBP15 (WH/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Electronic manual temperature control module Test J: The Electronic Automatic Temperature Control (EATC) Module Does Not Respond To The Scan Tool PINPOINT TEST J: THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) MODULE DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3462 J1-J2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3463 J3-J4 Normal Operation The EATC module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the EATC module. The EATC module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the auxiliary audio module, the digital versatile disc (DVD) player, the driver seat module (DSM) (if equipped), the power running board module, the parking aid module (if equipped), the power liftgate module and the climate controlled seat module (if equipped). Voltage for the EATC module is provided by circuits CBP37 (WH) and SBP15 (WH/RD). Circuit GD133 (BK) provides ground. DTC U0164 - sets in a module which had attempted to communicate with the EATC module and failed. Possible Causes - Fuse - Circuit CBP37 (WH) open - Circuit GD133 (BK) open - Circuit SBP15 (WH/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3464 - EATC module Test K: The Audio Unit Does Not Respond To The Scan Tool PINPOINT TEST K: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL K1-K2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3465 K2-K3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3466 K4 Normal Operation There are 2 types of audio units used on this vehicle, the base audio unit (Audiophile) and the THX(R) audio unit (if equipped). Both audio units communicate with the scan tool through the medium speed controller area network (CAN), circuits VDB06 (GY/OG) and VDB07 (VT/OG). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the audio unit. The audio unit shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the auxiliary audio module, the digital versatile disc (DVD) player, the driver seat module (DSM) (if equipped), the power running board module, the parking aid module (if equipped), the power liftgate module and the climate controlled seat module (if equipped). Voltage for the audio unit is provided by circuit SBP39 (WH/RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBP39 (WH/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - THX(R) amplifier Test L: The THX(R) Amplifier Does Not Respond To The Scan Tool PINPOINT TEST L: THE THX(R) AMPLIFIER DOES NOT RESPOND TO THE SCAN TOOL L1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3467 L1-L3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3468 L3-L4 Normal Operation The THX(R) amplifier communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the THX(R) amplifier. The THX(R) amplifier shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the auxiliary audio module, the digital versatile disc (DVD) player, the driver seat module (DSM) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the THX(R) amplifier is provided by circuits SBP38 (BN/RD) and SBP40 (VT/RD). Three circuits GD114 (BK/BU) provide ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBP38 (BN/RD) open - Circuit SBP40 (VT/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Audio unit Test M: The Satellite Radio Receiver Does Not Respond To The Scan Tool PINPOINT TEST M: THE SATELLITE RADIO RECEIVER DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3469 M1-M2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3470 M3-M4 Normal Operation The satellite radio receiver communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the satellite radio receiver. The satellite radio receiver shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the auxiliary audio module (if equipped), the digital versatile disc (DVD) player (if equipped), the driver seat module (DSM) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the satellite radio receiver is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBP03 (BU/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Satellite radio receiver Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3471 Test N: The Auxiliary Audio Module Does Not Respond To The Scan Tool PINPOINT TEST N: THE AUXILIARY AUDIO MODULE DOES NOT RESPOND TO THE SCAN TOOL N1-N2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3472 N2-N3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3473 N4 Normal Operation Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the auxiliary audio module. The auxiliary audio module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the auxiliary audio module is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBP03 (BU/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Auxiliary audio module Test O: The Digital Versatile Disc (DVD) Player Does Not Respond To The Scan Tool PINPOINT TEST O: THE DIGITAL VERSATILE DISC (DVD) PLAYER DOES NOT RESPOND TO THE SCAN TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3474 O1-O2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3475 O3-O4 Normal Operation The DVD player communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the DVD player. The DVD player is only on vehicles equipped with rear seat entertainment. The DVD player shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the DVD player is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBP03 (BU/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - DVD player Test P: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3476 PINPOINT TEST P: THE DRIVER SEAT MODULE DSM) DOES NOT RESPOND TO THE SCAN TOOL P1-P2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3477 P2-P3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3478 P4 Normal Operation The DSM communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the DSM. The DSM shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the DSM is provided by circuit SBB45 (GY/RD). Circuit GD143 (BK/VT) provides ground. DTC U0208 - sets in a module which had attempted to communicate with the DSM and failed. Possible Causes - Fuse - Circuit GD143 (BK/VT) open - Circuit SBB45 (GY/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - DSM Test Q: The Climate Controlled Seat Module Does Not Respond To The Scan Tool PINPOINT TEST Q: THE CLIMATE CONTROLLED SEAT MODULE DOES NOT RESPOND TO THE SCAN TOOL Q1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3479 Q2-Q4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3480 Q4-Q5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3481 Q6 Normal Operation The climate controlled seat module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the climate controlled seat module. The climate controlled seat module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the power running board module (if equipped), the parking aid module (if equipped) and the power liftgate module (if equipped). Voltage for the climate controlled seat module is provided by circuit SBB08 (VT/RD). Possible Causes - Fuse - Circuit GD138 (BK/WH) open - Circuit SBB08 (VT/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Climate controlled seat module Test R: The Power Running Board Module Does Not Respond To The Scan Tool PINPOINT TEST R: THE POWER RUNNING BOARD MODULE DOES NOT RESPOND TO THE SCAN TOOL R1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3482 R1-R2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3483 R3-R4 Normal Operation The power running board module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the power running board module. The power running board module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the parking aid module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the power running board module is provided by circuit SBB07 (WH/RD). Circuit GD143 (BK/VT) provides ground. DTC U0244 - sets in a module which had attempted to communicate with the power running board module and failed. Possible Causes - Fuse - Circuit GD143 (BK/VT) open - Circuit SBB07 (WH/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3484 - Circuit VDB07 (VT/OG) open (MS-CAN -) - Power running board module Test S: The Parking Aid Module Does Not Respond To The Scan Tool PINPOINT TEST S: THE PARKING AID MODULE DOES NOT RESPOND TO THE SCAN TOOL S1-S2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3485 S2-S3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3486 S4 Normal Operation The parking aid module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the parking aid module. The parking aid module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the power running board module (if equipped), the power liftgate module (if equipped) and the climate controlled seat module (if equipped). Voltage for the parking aid module is provided by circuit CBP35 (YE/GY). Circuit GD133 (BK) provides ground. DTC U0159 - sets in a module which had attempted to communicate with the parking aid module and failed. Possible Causes - Fuse - Circuit CBP35 (YE/GY) open - Circuit GD133 (BK) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Parking aid module Test T: The Power Liftgate Module Does Not Respond To The Scan Tool PINPOINT TEST T: THE POWER LIFTGATE MODULE DOES NOT RESPOND TO THE SCAN TOOL T1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3487 T1-T3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3488 T3-T4 Normal Operation The power liftgate module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the power liftgate module. The power liftgate module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the power running board module (if equipped), the parking aid module (if equipped) and the climate controlled seat module (if equipped). Voltage for the power liftgate module is provided by circuits SBP14 (BN/RD) and SBB27 (BU/RD). Circuit GD149 (BK/GY) provides ground. DTC U0230 - sets in a module which had attempted to communicate with the power liftgate module and failed. Possible Causes - Fuse - Circuit GD149 (BK/GY) open - Circuit SBP14 (BN/RD) open - Circuit SBB27 (BU/RD) open Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3489 - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Power liftgate module Test U: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST U: NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING U1-U2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3490 U2-U3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3491 U4-U6 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3492 U6-U7 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3493 U8-U10 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3494 U10-U14 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3495 U14-U17 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3496 U18-U22 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3497 U22-U26 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3498 U26-U30 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3499 U30-U33 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3500 U33-U35 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3501 U35-U39 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3502 U39-U42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3503 U43-U47 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3504 U47-U51 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3505 U51-U55 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3506 U55-U57 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3507 U58-U61 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3508 U62-U66 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3509 U67-U70 U71 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3510 Normal Operation The MS-CAN network uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. The smart junction box (SJB), the instrument cluster, the electronic manual temperature control module (if equipped), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the THX(R) amplifier (if equipped), the satellite radio receiver (if equipped), the auxiliary audio module (if equipped), the digital versatile disc (DVD) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), the power liftgate module, the driver seat module, and the climate controlled seat module (if equipped) all communicate with the scan tool using the MS-CAN network. Possible Causes - Circuit VDB06 (GY/OG) open, short to ground or voltage (MS-CAN +) - Circuit VDB07 (VT/OG) open, short to ground or voltage (MS-CAN -) - Circuit VDB06 (GY/OG) (MS-CAN +) and circuit VDB07 (VT/OG) (MS-CAN -) shorted together - SJB - Instrument cluster - Audio unit - THX(R) amplifier (if equipped) - EATC module (if equipped) - Electronic manual temperature control module (if equipped) - Auxiliary audio module (if equipped) - DVD player (if equipped) - Driver seat module (DSM) (if equipped) - Climate controlled seat module (if equipped) - Satellite radio receiver (if equipped) - Power running board module (if equipped) - Parking aid module (if equipped) - Power liftgate module (if equipped) Test V: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST V: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING V1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3511 V1-V2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3512 V3-V4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3513 V5-V6 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3514 V7-V8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3515 V8-V9 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3516 V10-V11 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3517 V12-V15 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3518 V15-V18 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3519 V18-V20 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3520 V20-V22 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3521 V22-V26 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3522 V26-V28 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3523 V28-V30 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3524 V31-V34 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3525 V35 Normal Operation The HS-CAN uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). The powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the air suspension module (if equipped) and the instrument cluster all communicate with the scan tool using the HS-CAN. Possible Causes - Circuit VDB04 (WH/BU) open, short to ground or voltage (HS-CAN +) - Circuit VDB05 (WH) open, short to ground or voltage (HS-CAN -) - Circuit VDB04 (WH/BU) (HS-CAN +) and circuit VDB05 (WH) (HS-CAN -) shorted together - PCM - RCM - TCM - ABS module - Instrument cluster - 4WD control module (if equipped) - Air suspension module (if equipped) Test W: No Power To The Scan Tool PINPOINT TEST W: NO POWER TO THE SCAN TOOL W1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3526 W2-W3 Normal Operation The scan tool is connected to the data link connector (DLC) to communicate with the high speed controller area network (HS-CAN) and the medium speed controller area network (MS-CAN) communications network. Voltage for the scan tool is provided by circuit SBP20 (GN/RD). Ground is provided by circuits GD113 (BK/YE) and GD138 (BK/WH). Possible Causes - Fuse - Circuit SBP20 (GN/RD) open - Circuit GD113 (BK/YE) open - Circuit GD138 (BK/WH) open - Scan tool Programming and Relearning PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3527 Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3528 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network > Page 3531 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3537 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3538 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3539 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3543 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3544 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3545 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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) 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. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 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. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3559 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3560 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3561 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3562 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3563 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3566 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3567 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3568 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3569 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3572 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3573 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3574 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. 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. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 3579 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3583 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation Body Control Module: Service and Repair Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the Original Module is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation Using the Integrated Diagnostic System IDS) When the Original Module is NOT Available NOTE: Following module installation, some modules require a separate learning procedure carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press check mark. 8. If the data is not available, the IDS displays screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation > Page 3590 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. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (TP) sensor, 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 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 (2007)) 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 3594 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 convened 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 (2007)) 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 3595 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 (2007)) 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 3596 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. 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 (2007)) 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 3597 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 (2007)) 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 3598 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 4% - Out of range, limp home default position. - Greater than or equal to 4% 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 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 3607 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3612 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Engine Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 3618 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Engine Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3623 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3624 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3627 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3628 orientation. 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 (2007)) 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 3629 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3630 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3631 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3632 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3633 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3634 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3635 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3636 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3637 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3638 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3639 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3640 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3641 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3642 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3643 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3644 Engine Control Module: Connector Views C175B (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3645 C175B (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3646 C175E (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3647 C175E (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal 1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the battery ground cable. 3. Disconnect the 2 PCM electrical connectors. 4. Remove the 2 bolts and the ground cable. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the PCM. 6. To install, reverse the removal procedure. Installation 1. Install the PCM. 2. Position the ground cable and install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the 3 PCM electrical connectors. 4. Connect the battery ground cable. 5. NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON. The warning indicator will remain on until PCM configuration is restored - Clear all restraints control module (RCM) continuous diagnostic trouble codes (DTCs) after Programmable Module Installation procedure has Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3650 been completed on the PCM. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3651 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. 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 needs 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 using a scan 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. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3655 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3656 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3657 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3662 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3663 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3667 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3668 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3669 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3670 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3679 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 3685 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Driveline Bump When Braking TSB 08-22-7 11/10/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Expedition This article supersedes TSB 08-4-13 to update the Issue, Service Procedure and remove the production fix date. ISSUE Some 2007-2008 Expedition vehicles may exhibit a bump feeling while braking to a stop below 10 MPH (16 Km/h). This procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE CAUTION APPLYING THIS PROCEDURE TO UNITS THAT DO NOT EXHIBIT THE COASTDOWN BUMP MAY RESULT IN WORSE SHIFT QUALITY. NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System/Portable Diagnostic Software (IDS/PDS) or equivalent and ID the vehicle. 2. Update the Power Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 57.8 and higher or 58.1 and higher. This new calibration is not included in the VCM 2008.9 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. a. Verify that the TCM shows 8L1P-7J104-AC (8L1P-7J104-BC for 2008 vehicles built after 12/3/2007) part number after reprogramming is complete. b. Select the following from IDS, Tool Box, Powertrain, OBD Test Modes, Mode Level 9 Vehicle info, TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking > Page 3691 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn: a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat Steps (a-b) a total of five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1300-1800 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. g. Repeat steps (e-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082207A 2007-2008 Expedition: 1.0 Hr. Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Test. Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 07-10-6 > May > 07 > Engine Controls - MIL ON/DTC's P2107/P2110 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2107/P2110 Set TSB 07-10-6 05/28/07 MIL ON - DTCS P2107/P2110 - NO DRIVEABILITY CONCERN FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a malfunction indicator light (MIL) on with diagnostic trouble codes (DTCs) P2107 and P2110 with no driveability concerns. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 48.13 and higher or 49.2 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 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 071006A 2007 Expedition/Navigator: 0.4 Hr. Check DTCs And Reprogram The PCM (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3700 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking > Page 3706 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn: a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat Steps (a-b) a total of five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1300-1800 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. g. Repeat steps (e-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082207A 2007-2008 Expedition: 1.0 Hr. Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Test. Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 3715 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3716 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3719 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3720 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3721 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3728 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3729 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3730 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3734 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3735 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3736 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 (2007)) 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) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3740 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3741 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3745 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3746 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3747 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3748 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR 106L (28 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3749 106L (28 Gallon) Fuel Tank (Part 2) 125L (33 Gallon) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3750 125L (33 Gallon) Fuel Tank (Part 2) Removal and Installation All fuel tanks 1. Remove the fuel tank. 106 L (28 gal.) fuel tank 2. Disconnect the supply and return fuel tubes quick connect couplings from the fuel filter. All fuel tanks 3. Remove the fuel tank heat shield retainer(s) and remove the fuel tank heat shield. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 5. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 6. NOTE: For the 106 L (28 gal.) fuel tank the fuel tank pressure sensor and vapor tube assembly and fresh air tube are serviced as an assembly. Remove the fuel tank pressure sensor and vapor tube assembly with the fresh air tube from the fuel tank. 125 L (33 gal.) fuel tank 7. Remove the fuel tank pressure sensor and vapor tube assembly from the fuel tank. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3751 - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3755 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3756 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 fuel, spark, and air flow. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3757 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. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3763 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3764 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3765 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3776 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3777 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3778 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3779 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-8 (Transmission - 6R75 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3780 View 151-10 (Transmission - 6HP26 4x4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3783 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3784 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3785 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3786 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 (2007)) 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 (2007)) 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 3789 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3790 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 (2007)) 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 3791 3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to aid in removal. 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. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3796 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 3800 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3804 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3807 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3808 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3813 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3814 orientation. 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 (2007)) 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 3815 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3816 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3817 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3818 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3819 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3820 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3821 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3822 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3823 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3824 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3825 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3826 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3827 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3828 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3829 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 that is generated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3834 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3838 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3841 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3842 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 orientation. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3868 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3869 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 VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3870 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 (2007)) 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 (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the variable camshaft timing (VCT) oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 that is generated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3878 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 (2007)) 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 (2007)) 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 (2007)) 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 downstream of the MAF/IAT sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Monitors/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 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3893 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 reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that 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 Typical Bank 1 Catalyst 2 HO2S Configuration Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3894 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 reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensor (HO2S) The HO2Ss provide the 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3899 Canister Purge Control Valve: Description and Operation EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE Typical 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 EVAP canister purge valve controls the flow of vapors by way of a solenoid, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal between 0 mA and 1,000 mA to control the EVAP canister purge valve. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3900 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER PURGE VALVE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3901 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3902 Exploded View Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3903 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 valve electrical connector. 3. Disconnect the intake manifold-to-EVAP canister purge valve vapor tube quick connect coupling. 4. Disconnect the EVAP canister-to-EVAP canister purge valve vapor tube quick connect coupling. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3904 5. Pull the EVAP canister purge valve release tab and slide the EVAP canister purge valve off the bracket. 6. To install, reverse the removal procedure. - Leak test the system. See: Testing and Inspection/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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 3908 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 3909 Exploded View Removal and Installation 1. NOTE: The evaporative emission canister vent solenoid and dust separator are an assembly. This assembly is removed with the evaporative emission canister vent solenoid. Refer to Evaporative Emission Canister Vent Solenoid. See: Leak Detection Valve/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3913 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3914 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3915 NOTE: The evaporative emission canister vent solenoid and dust separator are an assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-EVAP canister quick connect coupling. 5. Disconnect the EVAP canister purge valve vapor tube-to-EVAP canister quick connect coupling. 6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect coupling. 7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear. - Tighten to 20 Nm (15 lb-ft). 8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front. - Tighten to 20 Nm (15 lb-ft). 9. Remove the EVAP canister assembly bracket and exhaust Y-pipe-dual catalytic converter heat shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle. Tighten to 20 Nm (15 lb-ft). 10. NOTE: Lowering the corner of the EVAP canister assembly bracket will aid in disconnecting the EVAP canister vent solenoid electrical connector. Disconnect the EVAP canister vent solenoid electrical connector. 11. Remove the EVAP canister-to-EVAP canister assembly bracket bolts. - Tighten to 6 Nm (53 lb-in). 12. Remove the EVAP canister assembly from the EVAP canister assembly bracket. 13. Remove the canister vent solenoid and dust separator assembly from the EVAP canister. 14. To install, reverse the removal procedure. - Leak test the system. See: Testing and Inspection/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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3919 C4116 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3920 Leak Detection Valve: 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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3921 Leak Detection Valve: Service and Repair EVAPORATIVE EMISSION CANISTER VENT SOLENOID Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3922 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3923 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3924 NOTE: The evaporative emission canister vent solenoid and dust separator are an assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness. 4. Disconnect the fuel tank pressure sensor and vapor tube assembly-to-EVAP canister quick connect coupling. 5. Disconnect the EVAP canister purge valve vapor tube-to-EVAP canister quick connect coupling. 6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect coupling. 7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear. - Tighten to 20 Nm (15 lb-ft). 8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front. - Tighten to 20 Nm (15 lb-ft). 9. Remove the EVAP canister assembly bracket and exhaust Y-pipe-dual catalytic converter heat shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle. Tighten to 20 Nm (15 lb-ft). 10. NOTE: Lowering the corner of the EVAP canister assembly bracket will aid in disconnecting the EVAP canister vent solenoid electrical connector. Disconnect the EVAP canister vent solenoid electrical connector. 11. Remove the EVAP canister-to-EVAP canister assembly bracket bolts in the front of the canister. - Tighten to 6 Nm (53 lb-in). 12. Remove the canister vent solenoid and dust separator assembly from the EVAP canister. 13. To install, reverse the removal procedure. - Leak test the system. See: Testing and Inspection/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 (2007)) 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 SOLENOID EGR Vacuum Regulator Solenoid Vacuum Output (IN-HG) EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 sensor which provides feedback to the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 3936 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 system that functions in the same manner as a conventional differential pressure feedback EGR system. The various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR correction and inferred barometric pressure (BARO) at key on. The system provides the powertrain control module (PCM) with a differential pressure feedback EGR signal, identical to a traditional differential pressure feedback EGR system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 3937 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve EXHAUST GAS RECIRCULATION (EGR) VALVE Typical EGR Valve EGR Flowrate The EGR valve in the differential pressure feedback EGR 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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3941 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 connect couplings and remove the PCV tube. 4. Remove the 2 bolts and the PCV heater element. - Discard the O-ring seal. Installation 1. NOTE: Lubricate the O-ring seal with clean engine oil prior to Installation. Using a new O-ring seal, install the PCV heater element and the 2 bolts. Tighten to 6 Nm (53 lb-in). 2. Position the PCV tube and connect the quick connect couplings. 3. Connect the PCV heater element electrical connector. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3953 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3969 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 bolts and the accelerator pedal assembly. - To install, tighten to 12 Nm (9 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3973 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3974 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 (2007)) 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 1. Disconnect the battery ground cable. 2. Disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the air cleaner element. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3979 Installation 1. CAUTION: The air cleaner element must be fully seated into 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3983 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3984 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3985 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3986 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) 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 Special Tool(s) Special Tool(s) 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 a fire hazard. 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. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the pressure gauge. 3. NOTE: Open manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the pressure gauge and relieve the fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4000 C182 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4001 C183 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4002 C184 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4003 Fuel Injector: Diagrams C181 C182 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4004 C183 C184 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4005 C185 C186 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4006 C187 C188 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4007 Fuel Injector: Description and Operation FUEL INJECTORS Typical Fuel Injector 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 a 12-volt source from either the electronic engine control (EEC) power relay or fuel pump relay. The ground signal is controlled by the PCM. The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4008 Fuel Injector: Service and Repair FUEL RAIL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4009 Exploded View Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4010 - 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 battery ground cable. 2. Disconnect the fuel supply tube spring lock coupling. 3. Remove the air cleaner outlet pipe. 4. Disconnect the quick connect couplings and remove the crankcase vent tube. 5. Disconnect the generator wiring harness retainer from the air cleaner outlet pipe-to-throttle body (TB) adapter. 6. Remove the 4 bolts and the air cleaner outlet pipe-to-TB adapter. - Lubricate the air cleaner outlet pipe-to-TB adapter seal with clean engine coolant prior to installation. - To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. 8. Disconnect the electronic throttle control electrical connector. 9. Disconnect the throttle position (TP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4011 10. Disconnect the heated PCV intake fitting electrical connector. 11. Disconnect the 8 fuel injector electrical connectors. 12. Remove the 4 fuel rail bolts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the fuel rail and fuel injectors as an assembly. 14. Remove the 8 fuel injector-to-fuel rail locking clips. 15. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring 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. Separate the fuel injectors from the fuel rail. Discard the O-ring seals. 16. To install, reverse the removal procedure. - Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. 1. Release the fuel system pressure. 2. Remove the fuel tube safety clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4016 3. Install the special tool. 4. Close and push the special tool into the open side of the cage. 5. Separate the spring lock coupling. 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 spring lock 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4017 2. Fit the male fitting into the female end and push until the garter spring snaps over the flared end of the female end. 3. Make sure the spring lock coupling is engaged by pulling on the lines. 4. Install the fuel tube safety clip. Disconnect - Type II 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 repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard. 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. 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 cap off 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. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4018 2. Disconnect the safety clip from the male hose. 3. Install the special tool and press it into the spring lock coupling. 4. Separate the spring lock coupling. Connect - Type II 1. Inspect and clean both spring lock coupling ends. 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: Lubricate the tube end with clean engine oil to ease assembly. Align the fuel tubes spring lock coupling and push together until a click is heard. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4019 3. Pull on the spring lock coupling to make sure it is fully engaged, then install the safety clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4020 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. 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. 1. NOTE: Apply clean engine oil to the end of the tube or fitting before connecting. Connect the vapor tube fitting. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4021 Fuel Line Coupler: Service and Repair Quick Connect Coupling QUICK CONNECT COUPLING Disconnect - Type I 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 coupling. - Push the connector toward the tube to release pressure. - Push the release tab clockwise. - Disconnect the quick connect coupling. Connect - Type I 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 coupling. Disconnect - Type II 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 may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4022 - 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: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - 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. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube, 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 coupling. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4023 - Push the fitting toward the tube to release pressure. - Press the tab corners to release the fitting. - Disconnect the quick connect fitting. Connect - Type II 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 tube into the quick connect coupling. 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. Disconnect - Type III 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 may result in personal injury. - Do not smoke or carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as a cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and 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 repairing 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. - 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. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4024 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. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube quick connect coupling. - Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect. Connect - Type III 1. 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: Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Disconnect - Type IV 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 may 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 components. 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. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing 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. - 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. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4025 - 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. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube quick connect coupling. - Press the 2 fuel tube quick connect coupling buttons and pull the fuel tube to disconnect. Connect - Type IV 1. 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: Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 4030 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4041 Fuel Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4042 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4043 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement Technical Service Bulletin # 08S02 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4052 FSA VIN LIST ACTIVATED? Yes, available through the website by February 6, 2008. Owner names and addresses will be available by March 7, 2008. 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ 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. Non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ Refunds will only be provided for the cost associated with the replacement of the fuel rail. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 08S02 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4053 CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the Fuel Rail Assembly and injector 0-rings. SERVICE PROCEDURE Refer to SECTION 303-04: Fuel Charging and Controls on the online version of the appropriate workshop manual for the latest service procedure for removing and installing the fuel rail. Be sure to review all removal notes, cautions, and warnings. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4054 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4055 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4056 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > NHTSA08V057000 > Feb > 08 > Recall 08V057000: Fuel Rail Replacement Fuel Rail: Recalls Recall 08V057000: Fuel Rail Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006-2007 Ford/E-250 2006-2007 Ford/E-350 2006-2007 Ford/Expedition 2007 Lincoln/Navigator 2007 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V057000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline: Fuel Injection System: Fuel Rail POTENTIAL NUMBER OF UNITS AFFECTED: 57199 SUMMARY: Ford is recalling 57,199 M/Y 2006-2007 E-150, E-250, E-350, and M/Y 2007 Expedition and Lincoln Navigator vehicles equipped with 5.4L engines. The fuel rail cross-over hose may contain weak areas. As a result, the hose may crack, which could cause a fuel odor and/or fuel leak. CONSEQUENCE: Fuel leakage in the presence of an ignition source could result in a fire. REMEDY: Dealers will replace the fuel rail assembly. The recall is expected to begin during March 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement Technical Service Bulletin # 08S02 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4066 FSA VIN LIST ACTIVATED? Yes, available through the website by February 6, 2008. Owner names and addresses will be available by March 7, 2008. 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ 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. Non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ Refunds will only be provided for the cost associated with the replacement of the fuel rail. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 08S02 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4067 CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the Fuel Rail Assembly and injector 0-rings. SERVICE PROCEDURE Refer to SECTION 303-04: Fuel Charging and Controls on the online version of the appropriate workshop manual for the latest service procedure for removing and installing the fuel rail. Be sure to review all removal notes, cautions, and warnings. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4068 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4069 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 08S02 > Feb > 08 > Recall - Fuel Rail Assembly Replacement > Page 4070 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > NHTSA08V057000 > Feb > 08 > Recall 08V057000: Fuel Rail Replacement Fuel Rail: All Technical Service Bulletins Recall 08V057000: Fuel Rail Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006-2007 Ford/E-250 2006-2007 Ford/E-350 2006-2007 Ford/Expedition 2007 Lincoln/Navigator 2007 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V057000 NHTSA ACTION NUMBER: N/A COMPONENT: Fuel System, Gasoline: Fuel Injection System: Fuel Rail POTENTIAL NUMBER OF UNITS AFFECTED: 57199 SUMMARY: Ford is recalling 57,199 M/Y 2006-2007 E-150, E-250, E-350, and M/Y 2007 Expedition and Lincoln Navigator vehicles equipped with 5.4L engines. The fuel rail cross-over hose may contain weak areas. As a result, the hose may crack, which could cause a fuel odor and/or fuel leak. CONSEQUENCE: Fuel leakage in the presence of an ignition source could result in a fire. REMEDY: Dealers will replace the fuel rail assembly. The recall is expected to begin during March 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4075 Fuel Rail: Service and Repair FUEL RAIL Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4076 Exploded View Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4077 - 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 battery ground cable. 2. Disconnect the fuel supply tube spring lock coupling. 3. Remove the air cleaner outlet pipe. 4. Disconnect the quick connect couplings and remove the crankcase vent tube. 5. Disconnect the generator wiring harness retainer from the air cleaner outlet pipe-to-throttle body (TB) adapter. 6. Remove the 4 bolts and the air cleaner outlet pipe-to-TB adapter. - Lubricate the air cleaner outlet pipe-to-TB adapter seal with clean engine coolant prior to installation. - To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. 8. Disconnect the electronic throttle control electrical connector. 9. Disconnect the throttle position (TP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4078 10. Disconnect the heated PCV intake fitting electrical connector. 11. Disconnect the 8 fuel injector electrical connectors. 12. Remove the 4 fuel rail bolts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the fuel rail and fuel injectors as an assembly. 14. Remove the 8 fuel injector-to-fuel rail locking clips. 15. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring 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. Separate the fuel injectors from the fuel rail. Discard the O-ring seals. 16. To install, reverse the removal procedure. - Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 4082 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 which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 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 tube-to-fuel rail spring lock coupling. 4. Disconnect the evaporative emissions (EVAP) canister-to-EVAP canister purge valve vapor tube quick connect coupling. 5. Remove the transmission. 6. Disconnect the fuel tube-to-fuel filter outlet tube spring lock coupling. 7. Disconnect the EVAP canister purge valve vapor tube-to-EVAP canister quick connect coupling. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 106L (28 Gal) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4087 106L (28 Gal) Fuel Tank (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4088 127L (33.5 Gal) Fuel Tank (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4089 127L (33.5 Gal) Fuel Tank (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 which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4090 4. Remove the 3 fuel tank filler pipe-to-body screws. 5. Disconnect the fuel tank filler pipe vent tube-to-fuel tank pressure sensor and vapor tube assembly quick connect coupling. 6. Disconnect the fuel tank filler pipe vapor tube from the evaporative emissions (EVAP) canister fresh air tube. 7. Loosen the hose clamp and disconnect the fuel tank filler pipe hose-to-fuel tank. 8. Remove the 2 fuel tank filler pipe support brackets-to-frame bolts. - 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4099 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 4104 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4110 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 4115 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4116 Fuel Gauge Sender: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4117 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4118 C433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4119 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4120 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4121 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4122 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Fuel Tank Unit: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 4126 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 4127 C433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 4128 Fuel Tank Unit: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 4129 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4139 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4140 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4141 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4142 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair AIR CLEANER OUTLET PIPE Exploded View Removal 1. Remove the 2 bolts and the engine appearance cover. 2. Loosen the 2 air cleaner outlet pipe clamps. 3. Remove the air cleaner outlet pipe. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 4146 1. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. Position the air cleaner outlet pipe with the alignment indicator positioned as shown and tighten the 2 clamps. Tighten to 4 Nm (35 lb-in). 2. Position the engine appearance cover and install the 2 bolts. - Tighten to 5 Nm (44 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4150 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4151 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4152 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4157 Fuel Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4158 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4159 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 4163 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4164 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4165 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4170 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4171 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 (2007)) 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 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4175 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4176 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 (2007)) 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 4177 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. 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. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4178 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 4183 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation 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. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4190 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4191 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4192 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 (2007)) 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 4193 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 (2007)) 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, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4197 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 4200 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4201 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Page 4205 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 must be removed from the vehicle to be cleaned. Do not hold the throttle plate open with any object that could scratch the bore or plate while servicing or cleaning the throttle body. 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet pipe. 3. Disconnect the quick connect couplings and remove the crankcase vent tube. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Page 4206 4. Disconnect the generator wiring harness retainer from the air cleaner outlet pipe-to-throttle body (TB) adapter. 5. Remove the 4 bolts and position aside the air cleaner outlet tube-to-TB adapter. 6. Disconnect the electronic throttle control electrical connector. 7. Disconnect the throttle position (TP) sensor electrical connector. 8. Remove the 4 bolts and the vibration damper. 9. Remove the TB assembly. - Discard the TB O-ring seal. Installation 1. Using a new O-ring seal, position the TB and vibration damper and tighten the 4 bolts in 2 stages. - Stage 1: Tighten to 9 Nm (80 lb-in). - Stage 2: Tighten an additional 90 degrees. 2. Connect the TP sensor electrical connector. 3. Connect the electronic throttle control electrical connector. 4. Lubricate the air cleaner outlet pipe-to-TB adapter seal with clean engine coolant prior to installation. 5. Position the air cleaner outlet pipe-to-TB adapter and install the 4 bolts. - Tighten to 10 Nm (89 lb-in). 6. Connect the generator wiring harness retainer to the air cleaner outlet tube-to-TB adapter. 7. Position the crankcase vent tube and connect the quick connect couplings. 8. Install the air cleaner outlet pipe. 9. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4210 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 4213 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 the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4214 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Remove the throttle body (TB). 2. 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. Install the TB. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 4219 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. The motorized unit is energized above approximately 2,600 RPM. The motorized unit is commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to hold the shutter open. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 4220 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 (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4225 Firing Order: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 4238 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 4244 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4250 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 4255 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4261 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 4266 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4267 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4270 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4271 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4272 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4276 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4277 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4278 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 C111 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4284 C112 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4285 C113 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4286 C114 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4287 Ignition Coil: Diagrams C111 C112 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4288 C113 C114 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4289 C115 C116 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4290 C117 C118 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 4291 C174 C194 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4292 Ignition Coil: Description and Operation COIL ON PLUG (COP) Typical 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). COIL PACK Typical Four-Tower Coil Pack Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4293 Typical Six-Tower Coil Pack The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil. The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 4-tower, 6-tower horizontal and 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4294 Ignition Coil: Service and Repair IGNITION COIL-ON-PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4295 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4299 Ignition Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4300 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4301 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4307 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4314 Ignition Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4316 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 4326 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0345/P0349 TSB 08-16-14 08/18/08 DIAGNOSTIC TROUBLE CODES (DTCS) P0345 AND/OR P0349 - NO DRIVEABILITY SYMPTOMS, MIL LIGHT ON FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit the malfunction indicator light (MIL) on with DTC P0345 and/or P0349 without any driveability symptoms. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IT MAY BE NECESSARY TO REPLACE THE BANK 2 CAM POSITION (CMP) SENSOR CONNECTOR AND RE-ROUTE THE CMP HARNESS AWAY FROM THE POWER STEERING (PS) HOSE. THE PS HOSE MAY VIBRATE AGAINST THE HARNESS AND CAUSE INTERFERENCE WITH THE CMP SIGNAL. 1. Visually inspect the Bank 2 cam sensor wiring for evidence of interference with the PS hose. a. If interference, proceed to Step 2. b. If no interference, this procedure does not apply. Refer to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test DR. 2. With vehicle in park, start the engine and turn the steering wheel to the full lock position. Observe the PS pressure hose movement at full lock position. Repeat the full lock position several times to determine if hose movement under pressure is touching the CMP harness. a. If yes, turn off the engine and proceed to Step 3. b. If no interference, this procedure does not apply. Refer to PC/ED pinpoint test DR. 3. Remove air cleaner housing cover. NOTE DO NOT TRANSFER THE RIGHT ANGLE ELBOW (ON THE EXISTING CONNECTOR) TO THE NEW CONNECTOR. 4. Replace the CMP sensor connector C1367 with Pigtail Kit. Refer to included instruction sheet. 5. Using a tie strap, route the harness away from the PS hose by attaching it to the hole in the valve cover, located on the front left corner. 6. Install air cleaner housing cover. 7. Start engine and place in park. Check PS hose to CMP wire harness inter[ace. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081614A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The CMP Sensor Connector, Includes Time To Remove Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 08-16-14 > Aug > 08 > Engine Controls - MIL ON/DTC's P0345/P0349 > Page 4332 And Install Air Cleaner Housing Cover. (Do Not Use With 12650D, 9601A, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 14474 X2 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4333 View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4336 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4337 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 number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4338 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation LH camshaft position (CMP) sensor 1. Remove the air cleaner outlet pipe. All CMP sensors 2. Disconnect the CMP sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4342 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4343 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 deceleration between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4344 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor electrical connector. 4. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4350 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4356 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4357 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4358 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: Customer Interest Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 4367 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4373 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4374 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4375 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4376 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4377 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4378 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4379 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4380 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4381 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4382 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4383 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise Spark Plug: All Technical Service Bulletins Ignition/Fuel Systems - Misfire on Steady Cruise TSB 07-24-8 12/10/07 ENGINE MISFIRE DURING CRUISE WITH OR WITHOUT DTCS (MEXICO ONLY) FORD: 2007-2008 Expedition, F-150, F-250 LINCOLN: 2007-2008 Mark LI, Navigator ISSUE Some 2007-2008 Expedition, Navigator, Mark LT, F-150 and F-250 vehicles equipped with a 5.4 3V engines may exhibit engine misfire during cruise, rough run, hesitation, buck jerk, with or without diagnostic trouble codes (DTCs). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use Motorcraft(R) Carburetor Tune-Up Cleaner to clean engine combustion system. a. Disconnect canister purge line from the intake manifold. b. Attach a vacuum line to the purge port. c. At hot engine idle, allow the engine to ingest about a 1/2 to 2/3 of a can of Motorcraft(R) Carburetor Tune-Up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. Read the entire label on the Motorcraft(R) Carburetor Tune-Up Cleaner. Shake the can well before using and make sure to use at room temperature. d. Shut the engine off and allow it to soak for one hour. e. Start engine, allow the engine to ingest the remainder of the Motorcraft(R) Carburetor Tune-Up Cleaner. f. Reconnect canister purge vacuum line. g. Cycle engine between idle and 2500 RPM for about 5 minutes. 2. Inspect the spark plugs for abnormal fouling. 3. Replace fouled spark plugs. 4. Re-gap the spark plug to .035" (0.9 mm). 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 072408A 2007-2008 1.9 Hrs. Expedition/Navigator/F-150/F-250/Mark LT 5.4L 3V: Check DTCs, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 07-24-8 > Dec > 07 > Ignition/Fuel Systems - Misfire on Steady Cruise > Page 4388 Clean Combustion System, Remove Spark Plugs Inspect And, Replace As Necessary (Do Not Use With 12650D, 12405A, 1 2650D64) DEALER CODING CONDITION BASIC PART NO. CODE 12405 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions Spark Plug: All 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4394 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4395 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4396 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4397 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4398 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4399 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4400 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4401 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4402 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4403 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal Instructions > Page 4404 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 (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4405 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4406 Spark Plug: Application and ID Spark plug ........................................................................................................................................... ....................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4407 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4408 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4409 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4410 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: - Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior to spark plug removal. - Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - 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 (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4418 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4419 orientation. 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 (2007)) 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 4420 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4421 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4422 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4423 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4424 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4425 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4426 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4427 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4428 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4429 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4430 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4431 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4432 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4434 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4438 C2139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift 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 (2007)) 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 - Floor Shift > Page 4441 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Set the parking brake. 2. Remove the steering column shrouds. 3. Turn the ignition to the accessory position and apply the brake or actuate the brake shift interlock actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift > Page 4442 8. NOTE: During installation, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4447 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4448 orientation. 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 (2007)) 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 4449 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4450 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4451 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4452 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4453 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4454 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4455 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4456 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4457 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4458 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4459 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4460 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4461 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4462 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4463 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4468 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4469 orientation. 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 (2007)) 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 4470 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4471 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4472 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4473 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4474 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4475 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4476 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4477 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4478 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4479 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4480 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4481 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4482 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4483 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4484 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 4500 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4505 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4510 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4511 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4512 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 4518 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4523 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4528 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4529 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4530 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4535 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4536 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4543 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4544 orientation. 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 (2007)) 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 4545 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4546 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4547 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4548 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4549 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4550 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4551 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4552 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4553 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4554 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4555 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4556 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4557 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4558 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4559 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4560 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4565 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4566 orientation. 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 (2007)) 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 4567 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4568 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4569 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4570 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4571 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4572 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4573 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4574 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4575 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4576 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4577 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4578 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4579 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4580 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4581 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4586 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4587 orientation. 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 (2007)) 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 4588 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4589 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4590 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4591 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4592 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4593 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4594 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4595 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4596 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4597 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4598 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4599 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4600 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4601 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4602 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4608 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4609 orientation. 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 (2007)) 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 4610 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4611 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4612 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4613 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4614 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4615 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4616 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4617 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4618 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4619 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4620 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4621 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4622 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4623 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4624 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4625 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4626 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 (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4629 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4634 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4635 orientation. 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 (2007)) 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 4636 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4637 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4638 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4639 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4640 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4641 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4642 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4643 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4644 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4645 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4646 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4647 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4648 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4649 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4650 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4655 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4656 orientation. 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 (2007)) 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 4657 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4658 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4659 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4660 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4661 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4662 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4663 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4664 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4665 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4666 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4667 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4668 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4669 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4670 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4671 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 orientation. 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 (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4697 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - Driveline Bump When Braking TSB 08-22-7 11/10/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Expedition This article supersedes TSB 08-4-13 to update the Issue, Service Procedure and remove the production fix date. ISSUE Some 2007-2008 Expedition vehicles may exhibit a bump feeling while braking to a stop below 10 MPH (16 Km/h). This procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE CAUTION APPLYING THIS PROCEDURE TO UNITS THAT DO NOT EXHIBIT THE COASTDOWN BUMP MAY RESULT IN WORSE SHIFT QUALITY. NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System/Portable Diagnostic Software (IDS/PDS) or equivalent and ID the vehicle. 2. Update the Power Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 57.8 and higher or 58.1 and higher. This new calibration is not included in the VCM 2008.9 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. a. Verify that the TCM shows 8L1P-7J104-AC (8L1P-7J104-BC for 2008 vehicles built after 12/3/2007) part number after reprogramming is complete. b. Select the following from IDS, Tool Box, Powertrain, OBD Test Modes, Mode Level 9 Vehicle info, TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking > Page 4706 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn: a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat Steps (a-b) a total of five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1300-1800 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. g. Repeat steps (e-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082207A 2007-2008 Expedition: 1.0 Hr. Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Test. Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-10-6 > May > 07 > Engine Controls - MIL ON/DTC's P2107/P2110 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P2107/P2110 Set TSB 07-10-6 05/28/07 MIL ON - DTCS P2107/P2110 - NO DRIVEABILITY CONCERN FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a malfunction indicator light (MIL) on with diagnostic trouble codes (DTCs) P2107 and P2110 with no driveability concerns. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 48.13 and higher or 49.2 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 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 071006A 2007 Expedition/Navigator: 0.4 Hr. Check DTCs And Reprogram The PCM (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare PROM - Programmable Read Only Memory: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4715 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Driveline Bump When Braking TSB 08-22-7 11/10/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Expedition This article supersedes TSB 08-4-13 to update the Issue, Service Procedure and remove the production fix date. ISSUE Some 2007-2008 Expedition vehicles may exhibit a bump feeling while braking to a stop below 10 MPH (16 Km/h). This procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE CAUTION APPLYING THIS PROCEDURE TO UNITS THAT DO NOT EXHIBIT THE COASTDOWN BUMP MAY RESULT IN WORSE SHIFT QUALITY. NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System/Portable Diagnostic Software (IDS/PDS) or equivalent and ID the vehicle. 2. Update the Power Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 57.8 and higher or 58.1 and higher. This new calibration is not included in the VCM 2008.9 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. a. Verify that the TCM shows 8L1P-7J104-AC (8L1P-7J104-BC for 2008 vehicles built after 12/3/2007) part number after reprogramming is complete. b. Select the following from IDS, Tool Box, Powertrain, OBD Test Modes, Mode Level 9 Vehicle info, TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-22-7 > Nov > 08 > Engine, A/T Controls - Driveline Bump When Braking > Page 4721 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn: a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat Steps (a-b) a total of five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1300-1800 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. g. Repeat steps (e-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082207A 2007-2008 Expedition: 1.0 Hr. Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Test. Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-10-6 > May > 07 > Engine Controls - MIL ON/DTC's P2107/P2110 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2107/P2110 Set TSB 07-10-6 05/28/07 MIL ON - DTCS P2107/P2110 - NO DRIVEABILITY CONCERN FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a malfunction indicator light (MIL) on with diagnostic trouble codes (DTCs) P2107 and P2110 with no driveability concerns. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 48.13 and higher or 49.2 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 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 071006A 2007 Expedition/Navigator: 0.4 Hr. Check DTCs And Reprogram The PCM (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4730 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4738 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4739 orientation. 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 (2007)) 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 4740 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4741 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4742 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4743 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4744 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4745 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4746 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4747 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4748 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4749 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4750 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4751 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4752 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4753 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4754 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4758 C2139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift 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 (2007)) 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 - Floor Shift > Page 4761 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Set the parking brake. 2. Remove the steering column shrouds. 3. Turn the ignition to the accessory position and apply the brake or actuate the brake shift interlock actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift > Page 4762 8. NOTE: During installation, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4767 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4768 orientation. 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 (2007)) 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 4769 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4770 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4771 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4772 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4773 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4774 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4775 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4776 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4777 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4778 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4779 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4780 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4781 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4782 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4783 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4788 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4789 orientation. 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 (2007)) 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 4790 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4791 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4792 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4793 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4794 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4795 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4796 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4797 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4798 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4799 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4800 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4801 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4802 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4803 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4804 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4811 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4812 orientation. 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 (2007)) 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 4813 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4814 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4815 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4816 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4817 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4818 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4819 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4820 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4821 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4822 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4823 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4824 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4825 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4826 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4827 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4831 C2139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift 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 (2007)) 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 - Floor Shift > Page 4834 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Set the parking brake. 2. Remove the steering column shrouds. 3. Turn the ignition to the accessory position and apply the brake or actuate the brake shift interlock actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift > Page 4835 8. NOTE: During installation, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4840 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4841 orientation. 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 (2007)) 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 4842 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4843 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4844 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4845 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4846 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4847 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4848 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4849 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4850 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4851 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4852 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4853 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4854 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4855 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4856 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4861 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4862 orientation. 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 (2007)) 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 4863 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4864 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4865 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4866 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4867 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4868 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4869 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4870 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4871 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4872 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4873 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4874 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4875 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4876 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4877 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 4899 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-6-1 > Apr > 09 > A/T - 6R75 Squawk Noise On Hard Downshifts Clutch: Customer Interest A/T - 6R75 Squawk Noise On Hard Downshifts TSB 09-6-1 04/06/09 6R75 TRANSMISSION - SQUAWK NOISE DURING POWER/FORCED DOWNSHIFT FORD: 2007-2008 Expedition This article supersedes TSB 08-19-8 to update the vehicle model years and remove the production fix date. ISSUE Some 2007-2008 Expedition vehicles equipped with a 6R75 transmission may exhibit a squawk type noise during hard acceleration down shifts (4-3), (5-3) and (6-3) downshifts. The noise is produced during the release of the overdrive clutch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow Workshop Manual (WSM), Section 307-01B to replace the overdrive friction plates. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 090601A 2007-2008 Expedition 10.9 6R75 Transmission 4X2: Hrs. Replace The Overdrive Friction Plates, Includes Time To Remove And Install Transmission. (Do Not Use With 7000A, 7000A2, 7000AXQ, 7000AZT) 090601A 2007-2008 Expedition 11.6 6R75 Transmission 4X4: Hrs. Replace The Overdrive Friction Plates, Includes Time To Remove And Install Transmission And, Transfer Case. (Do Not Use With 7000A, 7000A2, 7OOOAXQ, 7000AZT) DEALER CODING CONDITION BASIC PART NO. CODE 7B164 D4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-6-1 > Apr > 09 > A/T - 6R75 Squawk Noise On Hard Downshifts > Page 4908 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 Clutch: Customer Interest A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. NOTE DO NOT REMOVE FRONT PUMP SEAL. NOTE DO NOT REPLACE THE FLUID FILTER. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 > Page 4913 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-6-1 > Apr > 09 > A/T - 6R75 Squawk Noise On Hard Downshifts Clutch: All Technical Service Bulletins A/T - 6R75 Squawk Noise On Hard Downshifts TSB 09-6-1 04/06/09 6R75 TRANSMISSION - SQUAWK NOISE DURING POWER/FORCED DOWNSHIFT FORD: 2007-2008 Expedition This article supersedes TSB 08-19-8 to update the vehicle model years and remove the production fix date. ISSUE Some 2007-2008 Expedition vehicles equipped with a 6R75 transmission may exhibit a squawk type noise during hard acceleration down shifts (4-3), (5-3) and (6-3) downshifts. The noise is produced during the release of the overdrive clutch. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow Workshop Manual (WSM), Section 307-01B to replace the overdrive friction plates. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 090601A 2007-2008 Expedition 10.9 6R75 Transmission 4X2: Hrs. Replace The Overdrive Friction Plates, Includes Time To Remove And Install Transmission. (Do Not Use With 7000A, 7000A2, 7000AXQ, 7000AZT) 090601A 2007-2008 Expedition 11.6 6R75 Transmission 4X4: Hrs. Replace The Overdrive Friction Plates, Includes Time To Remove And Install Transmission And, Transfer Case. (Do Not Use With 7000A, 7000A2, 7OOOAXQ, 7000AZT) DEALER CODING CONDITION BASIC PART NO. CODE 7B164 D4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-6-1 > Apr > 09 > A/T - 6R75 Squawk Noise On Hard Downshifts > Page 4919 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 Clutch: All Technical Service Bulletins A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. NOTE DO NOT REMOVE FRONT PUMP SEAL. NOTE DO NOT REPLACE THE FLUID FILTER. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 > Page 4924 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Page 4925 Clutch: Service and Repair Clutch Application Chart General Specifications Clutch Application Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 4934 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4939 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4944 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4945 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4946 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 4952 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 4957 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4962 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4963 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4964 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid (6R75) .................................................................................................................. ............................................. 11.0 quarts (10.5 liters) NOTE: Indicates only approximate dry fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4969 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... .......................................... MERCON SP XT-6-QSP Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 6HP26 Automatic Transmission Fluid - A/T: Testing and Inspection 6HP26 Automatic Transmission 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: 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 PARK, the engine at idle (550-750 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 PARK position. 2. With the engine idling (550-750 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 lb-ft). 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 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 amber. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 6HP26 Automatic Transmission > Page 4972 Fluid - A/T: Testing and Inspection 6R75 Automatic Transmission 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. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. This transmission is equipped with an internal thermal bypass located in the case. This internal thermal bypass valve will shut off fluid flowing to the fluid cooler if the fluid temperature falls below normal operating temperature. High Fluid Level CAUTION: 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 cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission failure. If an overfill reading is indicated, remove any excessive fluid. 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. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. 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. Add fluid using the refill procedure. Fluid Condition Check 1. Check the fluid level. 2. Remove the fluid fill plug and fluid level indicator and allow the fluid to drip onto a facial tissue and examine the stain. 3. Observe the color and the odor. The color under normal circumstances should be dark reddish, 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. new oil-to-air (OTA) cooler must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill 6HP26 Automatic Transmission Transmission Fluid Drain and Refill Special Tool(s) Material Drain 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 the transmission fluid pan and allow the fluid to drain. 3. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4975 4. Clean and inspect the transmission fluid pan and magnet. Refill 1. Install the fluid pan gasket. 2. Install the fluid pan and bolts. ^ Tighten to 12 Nm (9 lb-ft). 3. 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. 4. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4976 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. 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 (550-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level. 7. 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 with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. 8. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). 6R75 Automatic Transmission Transmission Fluid Drain and Refill Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4977 Special Tool(s) Material Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some fluid leakage may occur when removing the fluid fill plug. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4978 3. Remove the transmission fluid pan and allow the fluid to drain. 4. Install the transmission fluid pan. ^ Tighten to 14 Nm (10 lb-ft). Transmission Fluid Refill CAUTION: This procedure contains the air purge steps required to purge air from the cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. 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. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. ^ Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill enabling you to start the engine. ^ The cold level range shown in the procedure allows the vehicle to be driven. ^ The vehicle should be driven to allow the transmission fluid temperature to reach 85°C-88°C (185°F-190°F) in order to purge the air from the transmission cooling system. ^ Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range 80°C-85°C (175°F-185°F). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to the transmission as an initial fill if: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4979 ^ the transmission has been overhauled. ^ a new mechatronic assembly has been installed. ^ the transmission fluid pan or fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission through the fluid fill hole. 2. Check the transmission fluid level cold. 1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90°F-110°F). ^ Using the scan tool and the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm). 3. Separate the fluid level indicator from the fill plug. 4. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 5. Add clean transmission fluid to the cold level location as shown in the illustration. 6. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4980 7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the cooling system, eliminating any trapped air in the cooling system. ^ With the engine idling (600-750 rpm) in PARK, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). 8. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. 9. Separate the fluid level indicator from the fill plug. 10. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 11. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4981 12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid in this procedure. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the special tool into the fluid fill hole. 2. Fill the special tool with approximately 0.47L (1 pt) of clean automatic transmission fluid. 3. Hang the special tool under the vehicle, upright and close to the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4982 4. Connect the special tools. ^ Connect the open end of the fluid hose from the special tool onto the special tool from the transmission case. 5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission. 6. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 7. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4983 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Removing Transmission Fluid NOTE: To get an accurate fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, fluid must be removed to the correct level. Use the special tools to extract any excessive fluid. 2. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The fluid level must be at the upper level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this until a consistent reading is established. 3. Install the fluid fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4984 ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4985 Fluid - A/T: Service and Repair Transmission Fluid Level Check Transmission Fluid Level Check Special Tool(s) Material CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler, cooler lines have been carried out the vehicle must be driven to get the transmission fluid to a temperature of 88°C (190°F) in order to purge the air from the cooling system. 1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK. 2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the fluid level indicator from the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4986 5. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. 6. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch mark. 7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4987 Fluid - A/T: Service and Repair 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 leaks 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 fluid cooler 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. 6R75 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 leaks 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4988 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Material Removal 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the fluid to drain. 4. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4992 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case, carefully remove the seal without scratching the case. 2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean automatic transmission fluid. 3. NOTE: The fluid filter may be reused if no excessive contamination is indicated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4993 Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. 6. Install the fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the refill procedure, fill and check the transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4998 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pushpin and move the air deflector aside. 3. Remove the transmission cooler tube secondary latches. 4. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler hoses. 5. Remove the transmission fluid cooler tube bracket nut from the front of the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4999 6. Remove the transmission fluid cooler tube bracket from the side of the transmission. 7. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully remove them from the case if retained. Remove the bolt and disconnect the transmission fluid cooler tubes from the transmission. 8. Disconnect the electrical harness from the transmission cooler tubes. 9. Remove the 4 nuts and lower the front sway bar. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5000 10. CAUTION: Only use hand tools when removing the engine mount nuts or damage to the engine mount may occur. For four wheel drive (4WD), remove the LH engine mount nuts and lift the engine to gain clearance for the trans cooler tubes. 11. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. 2. Install the bolt and transmission fluid cooler tube bracket to the side of the transmission. ^ Tighten to 48 Nm (35 lb-ft). 3. Install the nut and transmission fluid cooler tube bracket to the front of the engine. ^ Tighten to 40 Nm (30 lb-ft). 4. Connect the transmission fluid cooler tubes to the transmission fluid cooler hoses. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5001 5. Install the transmission cooler tube secondary latches. 6. Reposition the air deflector and install the pushpin. 7. Position the sway bar in place and install the 4 nuts. ^ Tighten to 55 Nm (41 lb-ft). 8. CAUTION: Only use hand tools when installing the engine mount nuts or damage to the engine mount may occur. For 4WD, lower the engine and install the LH engine mount nuts. ^ Tighten to 175 Nm (129 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5002 9. Connect the electrical harness to the transmission cooler tubes. 10. NOTE: Inspect the case to make sure that the old O-rings are not stuck in the case. NOTE: Install new O-rings on the ends of the cooler lines prior to installing. Install new O-rings on the transmission fluid cooler tubes. 11. NOTE: Inspect the case to make sure that the old O-rings are not stuck in the case. NOTE: Install new O-rings on the ends of the cooler lines prior to installing. Position the transmission fluid cooler tubes into the transmission, then install the bolt. ^ Tighten to 25 Nm (18 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5003 12. Fill the transmission with fluid and verify correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5004 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hoses Transmission Fluid Cooler Hoses Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5005 Removal 1. Remove the upper radiator cover. 1 Remove the fasteners. 2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamps. 3. Disconnect the auxiliary transmission fluid cooler inlet hose from the coolers. 4. With the vehicle in NEUTRAL, position it on a hoist. 5. Move the flexible air deflector aside, then remove and discard the transmission fluid cooler tube secondary latches. 6. Using the special tool, disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes. 7. Remove and discard the transmission fluid cooler hose clamps. 8. Disconnect the transmission fluid cooler hoses from the coolers. Installation 1. Connect the transmission fluid cooler hoses to the coolers. 2. Install new transmission fluid cooler hose clamps. 3. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes. 4. Install new transmission fluid cooler tube secondary latches, then move the flexible air deflector back into place. 5. Connect the auxiliary transmission fluid cooler inlet hose to the coolers. 6. Install new auxiliary transmission fluid cooler inlet hose clamps. 7. Install the upper radiator cover. 1 Install the fasteners. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 5006 8. Fill the transmission with fluid and verify correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 6HP26 Automatic Transmission Fluid Pan: Specifications 6HP26 Automatic Transmission Transmission fluid pan bolts................................................................................................................. ........................................................... 12 Nm (9 lb-ft) Tighten the bolts in a crisscross pattern Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 6HP26 Automatic Transmission > Page 5011 Fluid Pan: Specifications 6R75 Automatic Transmission Transmission fluid pan bolts................................................................................................................. ......................................................... 14 Nm (10 lb-ft) Tighten the bolts in a crisscross pattern Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5012 Fluid Pan: Service and Repair Fluid Pan, Gasket and Filter Material Removal 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the fluid to drain. 4. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5013 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case, carefully remove the seal without scratching the case. 2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean automatic transmission fluid. 3. NOTE: The fluid filter may be reused if no excessive contamination is indicated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5014 Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. 6. Install the fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the refill procedure, fill and check the transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Fluid Pump: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5023 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Fluid Pump: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5029 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 5085 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 5090 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5095 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5096 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5097 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 5103 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 5108 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5113 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5114 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5115 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Seals and Gaskets: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5124 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 07-5-5 > Mar > 07 > A/T 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 Seals and Gaskets: Customer Interest A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. NOTE DO NOT REMOVE FRONT PUMP SEAL. NOTE DO NOT REPLACE THE FLUID FILTER. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 07-5-5 > Mar > 07 > A/T 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 > Page 5129 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Seals and Gaskets: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5135 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 Seals and Gaskets: All Technical Service Bulletins A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. NOTE DO NOT REMOVE FRONT PUMP SEAL. NOTE DO NOT REPLACE THE FLUID FILTER. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 07-5-5 > Mar > 07 > A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 > Page 5140 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5141 Seals and Gaskets: By Symptom Technical Service Bulletin # 10-18-1 Date: 100927 A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5142 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Technical Service Bulletin # 07-5-5 Date: 070319 A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5143 NOTE DO NOT REMOVE FRONT PUMP SEAL. NOTE DO NOT REPLACE THE FLUID FILTER. 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5144 Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Technical Service Bulletin # 07-5-5 Date: 070319 A/T - 2-3/4-5 Shift Flare/MIL ON/DTC's P07782/P0784 TSB 07-5-5 03/19/07 6R75 TRANSMISSION 2-3 AND/OR 4-5 SHIFT FLARE, POSSIBLE WRENCH LAMP ILLUMINATED WITH DTC P0782 AND/OR P0784 FORD: 2007 Expedition This article supersedes TSB 07-3-7 to remove the production fix date. ISSUE Some 2007 Expedition vehicles exhibit a 2-3 shift flare and/or a 4-5 shift flare. The wrench light may be illuminated and diagnostic trouble code(s) (DTCs) P0782 and/or P0784 may be present in the transmission control module (TCM) memory. This condition may be caused by damaged direct clutch (B Clutch) seals. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS CONCERN IS FOR VEHICLES WITH LESS THAN 1000 MILES ONLY. SERVICE PROCEDURE Replace the two (2) direct clutch seals on the direct clutch cylinder and shaft assembly only. It is NOT necessary to completely overhaul the transmission. Follow the disassembly procedures as shown in the Workshop Manual (WSM), Section 307-01 B through the removal of the Forward Clutch (A Clutch), the front planetary gear set, the Overdrive Clutch (E Clutch) and the Direct Clutch (B Clutch). NOTE DISASSEMBLY OF THE CLUTCH PACKS AND THE SEPARATION OF THE FRICTION AND STEELS IS NOT REQUIRED FOR THIS REPAIR. THERE IS NO NEED TO PERFORM CLUTCH PACK END CLEARANCE CHECKS. IT IS ONLY NECESSARY TO REPLACE THE DIRECT CLUTCH SEALING RINGS. IT IS NOT NECESSARY TO DISASSEMBLE THE ENTIRE TRANSMISSION TO REPLACE THESE SEALS. NOTE DO NOT DISCARD CENTER SUPPORT RUBBER FEED TUBES. NOTE DO NOT REMOVE FRONT PUMP SEAL. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5145 NOTE DO NOT REPLACE THE FLUID FILTER. 1. Remove the two (2) seal rings from the direct (B Clutch) cylinder. Discard the seal rings and replace with new ones. See Figure 1 for proper direct (B Clutch) seal locations and alignment of the scarf cut seals. 2. Reassemble in reverse order following the WSM, Section 307-01B. 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 070505A 2007 Expedition 4X4: 8.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes Time To Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) 070505A 2007 Expedition 4X2: 7.0 Hrs. Replace The Two Direct Clutch Seals On The Direct Clutch Cylinder And Shaft Assembly. Includes time to Check DTCs, R And I Transmission, Also Includes Shift Cable Adjustment After Re-assembly (Do Not Use Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5146 With 5200A, 5200B, 7000A, 700A2, 7000A6, 7000A7, 7000A12, 7000F, 4602A, 7191A, 7191A1, 7326C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7A098 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tool(s) Material NOTE: Rear wheel drive (RWD) shown, four wheel drive (4WD) similar. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5149 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. RWD vehicles 2. Remove the rear driveshaft. 3. Remove and discard the output shaft flange nut. 4. Remove the output shaft flange. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5150 5. Using the special tools, remove the output shaft seal. 4WD vehicles 6. Remove the transfer case. 7. Using the special tools, remove the output shaft seal. Installation RWD vehicles 1. Position a new output shaft seal. 2. Using the special tool, install the output shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5151 3. Install the output shaft flange. 4. Install a new output shaft flange nut. ^ Tighten to 80 Nm (59 lb-ft). 5. Install the rear driveshaft. 4WD vehicles 6. Position the output shaft seal. 7. Using the special tool, install a new output shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5152 8. Install the transfer case. All vehicles 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. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical connector. 10. 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. 11. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 12. With the special tool connected, the engine idling (550-750 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. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5153 14. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5154 3. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud. 4. 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. 5. Remove the transmission fluid pan and allow the fluid to drain. 6. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5155 7. Remove and discard the transmission fluid filter. 8. Clean and inspect the transmission fluid pan and magnet. 9. Press the release tab and pull down on the bulkhead connector retainer. 10. With the release tab down, pull the outer shell of the bulkhead electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5156 11. 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. 12. NOTE: During removal of the mechatronic assembly, the thermal bypass valve, pump adapter seal and one or more center support seals may become dislodged. Save these components for reuse during assembly. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly. 13. Remove the park rod actuating plate. 14. Remove the manual control lever. 1 Remove the roll pin. 2 Slide the manual control lever shaft out of the case. 3 Hold the spacer to keep it from falling out of the case. 4 Remove the manual valve inner lever and the park rod as an assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5157 15. Remove and discard the manual control lever seal. Installation 1. Position a new manual control lever seal in place. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5158 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 lb-in). 6. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time. Verify the 4 rubber feed tubes for the center support are in place. 7. Verify the thermal bypass valve is in the case. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5159 8. Verify the rubber adapter is in place. 9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit. Position the mechatronic assembly in place and loosely install the 10 bolts. 1 Align the manual valve and control lever linkage. 10. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 8 Nm (71 lb-in). 11. Install new O-rings on the outer shell of the bulkhead electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5160 12. 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. 13. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. 14. Install a new transmission fluid filter. 15. Install the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5161 16. Install the fluid pan and bolts. ^ Tighten to 12 Nm (9 lb-ft). 17. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 18. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Connect the selector lever cable onto the ball stud and move the locking tab down. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 19. If equipped, install the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5162 20. 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. 21. 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. 22. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 23. With the special tool connected, the engine idling (550-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level. 24. 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 with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5163 25. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5164 Seals and Gaskets: Service and Repair 6R75 Automatic Transmission Output Shaft Seal Output Shaft Seal Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5165 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Rear wheel drive (RWD) vehicles 2. Remove the rear driveshaft. 3. NOTE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to removing the nut, remove the stake to prevent damage to the output shaft. Remove and discard the output shaft flange nut. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5166 4. Remove the output shaft flange. 5. Using the special tools, remove the output shaft seal. Four wheel drive (4WD) vehicles 6. Remove the transfer case. 7. Using the special tools, remove the output shaft seal. Installation RWD vehicles 1. Position a new output shaft seal. 2. Using the special tool, install the output shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5167 3. Install the output shaft flange. 4. Install a new output shaft flange nut. ^ Tighten to 60 Nm (44 lb-ft). ^ After installing the new nut, it must be staked at the slots to prevent it from coming loose. 5. Install the rear driveshaft. 4WD vehicles 6. Position the output shaft seal. 7. Using the special tool, install a new output shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5168 8. Install the transfer case. All vehicles 9. Fill and check the transmission fluid. Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the heat shield. 3. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5169 4. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. 5. Remove the transmission fluid pan and allow the fluid to drain. 6. Remove and discard the transmission fluid filter. 7. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5170 8. 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. 9. Pull the release tab and pull down on the bulkhead connector retainer. 10. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. With the release tab down, pull the outer shell of the bulkhead electrical connector out of the transmission control module (TCM). 11. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Pull the bulkhead electrical connector out of the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5171 12. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly. 13. Remove the park rod actuating plate. 14. Remove the manual control lever. 1 Remove the roll pin. 2 Slide the manual control lever shaft out of the case. 3 Hold the spacer to keep it from falling out of the case. 4 Remove the manual valve inner lever and the park rod as an assembly. 15. Remove and discard the manual control lever seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5172 Installation 1. Position a new manual control lever seal in place. 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 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5173 6. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time. Verify the 4 rubber feed tubes for the center support are in place. 1 Black feed tube. 2 Green feed tube. 3 Blue feed tube. 7. Verify the rubber adapter is in place. 8. Verify the thermal bypass valve is in the case. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5174 9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Position the mechatronic assembly in place and loosely install the 11 bolts. 1 Align the manual valve and control lever linkage. 10. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-in). 11. CAUTION: Do not touch the electrical connector pins. Electrostatic discharge may occur and will cause damage to the mechatronic unit. With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5175 12. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. 13. Install a new transmission fluid filter. 14. NOTE: The fluid pan gasket can be reused if not damaged. Install the transmission fluid pan gasket if necessary. 15. Install the fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5176 17. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Connect the selector lever cable onto the ball stud and move the locking tab down. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 18. If equipped, install the heat shield. 19. Using the refill procedure, fill and check the transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5182 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5183 orientation. 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 (2007)) 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 5184 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5185 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5186 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5187 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5188 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5189 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5190 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5191 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5192 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5193 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5194 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5195 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5196 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5197 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5198 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5199 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5204 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5205 orientation. 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 (2007)) 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 5206 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5207 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5208 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5209 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5210 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5211 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5212 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5213 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5214 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5215 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5216 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5217 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5218 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5219 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5220 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5225 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5226 orientation. 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 (2007)) 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 5227 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5228 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5229 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5230 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5231 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5232 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5233 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5234 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5235 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5236 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5237 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5238 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5239 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5240 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5241 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5247 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5248 orientation. 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 (2007)) 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 5249 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5250 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5251 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5252 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5253 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5254 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5255 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5256 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5257 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5258 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5259 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5260 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5261 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5262 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5263 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5264 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5265 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 5268 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5273 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5274 orientation. 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 (2007)) 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 5275 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5276 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5277 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5278 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5279 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5280 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5281 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5282 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5283 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5284 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5285 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5286 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5287 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5288 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5289 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5294 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5295 orientation. 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 (2007)) 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 5296 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5297 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5298 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5299 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5300 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5301 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5302 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5303 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5304 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5305 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5306 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5307 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5308 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5309 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5310 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5336 C2139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift 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 (2007)) 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 - Floor Shift > Page 5339 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Set the parking brake. 2. Remove the steering column shrouds. 3. Turn the ignition to the accessory position and apply the brake or actuate the brake shift interlock actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift > Page 5340 8. NOTE: During installation, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams C2096 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism Shifter A/T: Service and Repair Selector Lever Mechanism Selector Lever Mechanism Removal 1. Remove the instrument panel lower finish panel. 2. Remove the steering column lower shroud. 1 Remove the screws and the lower shroud. 3. Remove the steering column upper shroud. 4. Remove the instrument panel (IP) cluster-to-shroud trim. 5. Remove the RH IP cluster trim screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5367 6. Remove the LH IP cluster trim screw and pull the IP cluster trim from the IP. 7. If equipped, disconnect the in-vehicle temperature sensor connector. 8. Disconnect the dimmer switch electrical connector and remove the IP cluster trim. 9. Remove the upper IP cluster screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5368 10. Remove the RH lower IP cluster screw. 11. Remove the LH lower IP cluster screw and position the IP cluster aside. 12. Disconnect the selector lever cable. 13. Remove the locking pin and the park lock cable (PLC). 1 Remove and discard the locking pin. 2 Disconnect the PLC. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5369 14. Disconnect the transmission control (TC) switch electrical connector and the harness from the retaining clips. 15. Remove the selector lever bolt. 16. Remove the selector lever. 17. Remove the selector lever mechanism lower bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5370 18. Disconnect the brake shift interlock actuator (BSIA) electrical connector and remove the selector lever mechanism upper bolts and the selector lever mechanism from the vehicle. 19. Remove the BSIA from the selector lever mechanism. 1 Pull the BSIA override button. 2 Remove the BSIA screw. 3 Gently pry the clip up and remove the BSIA. Installation 1. Install the BSIA onto the selector lever mechanism. 1 Pull the BSIA override button. 2 Align the selector lever tab into the BSIA. 3 Position and secure the BSIA with the clip. 4 Install the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5371 2. Install the selector lever mechanism into the vehicle, install the upper bolts and connect the BSIA electrical connector. ^ Tighten to 6 Nm (53 lb-in). 3. Install the selector lever mechanism lower bolt. ^ Tighten to 6 Nm (53 lb-in). 4. Install the selector lever. ^ Tighten to 18 Nm (13 lb-ft). 5. Connect the TC switch electrical connector and the harness into the retaining clips. 6. Install the locking pin and the PLC. 1 Connect the PLC. 2 Install a new locking pin. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5372 7. Connect the selector lever cable. 8. Position the IP cluster and install the LH lower IP cluster screw. 9. Install the RH lower IP cluster screw. 10. Install the upper IP cluster screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5373 11. Position the IP cluster trim and connect the dimmer switch electrical connector. 12. If equipped, connect the in-vehicle temperature sensor connector. 13. Install the LH IP cluster trim screw. 14. Install the RH IP cluster trim screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5374 15. Install the IP cluster-to-shroud trim. 16. Install the steering column upper shroud. 17. Install the steering column lower shroud. 18. Install the instrument panel lower finish panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5375 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Vehicles Equipped With a 6R75 Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5376 Vehicles Equipped With a 6HP26 Transmission Removal 1. NOTE: 6R75 transmission selector lever shown, 6HP26 similar. Remove the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5377 2. Remove the screw and the console upper trim. 3. Remove and discard the RH selector lever knob cover. 1 Start at the bottom rear only. 2 Work towards the top. 4. Remove and discard the LH selector lever knob cover. 1 Start at the bottom rear only. 2 Work towards the top. 5. Remove and discard the RH selector lever knob screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5378 6. Remove and discard the LH selector lever knob screw. 7. Disconnect the transmission control (TC) switch electrical connector and remove the selector lever knob. Installation 1. Connect the transmission control (TC) switch electrical connector and install the selector lever knob. 2. Install a new LH selector lever knob screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5379 3. Install a new RH selector lever knob screw. 4. NOTE: Wood trimmed vehicles have a rubber damper not found on other trim levels. Install a new LH selector lever knob cover. 5. NOTE: Wood trimmed vehicles have a rubber damper not found on other trim levels. Install a new RH selector lever knob cover. 6. Install the console upper trim and the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5380 7. Install the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5381 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Vehicles Equipped With a 6R75 Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5382 Vehicles Equipped With a 6HP26 Transmission Removal All vehicles 1. NOTE: 6R75 transmission selector lever shown, 6HP26 similar. Remove the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5383 2. Remove the screw and the console upper trim. 3. Remove and discard the RH selector lever knob cover. 1 Start at the bottom rear only. 2 Work towards the top. 4. Remove and discard the LH selector lever knob cover. 1 Start at the bottom rear only. 2 Work towards the top. 5. Remove and discard the RH selector lever knob screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5384 6. Remove and discard the LH selector lever knob screw. 7. Disconnect the transmission control (TC) switch electrical connector and remove the selector lever knob. 8. Lift the tabs on the selector lever bezel and lift the bezel for access to the electrical harness. 9. Disconnect the electrical harness from the selector lever housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5385 Vehicles equipped with a 6R75 transmission 10. Disconnect the electrical harness from the bezel. Installation Vehicles equipped with a 6R75 transmission 1. Connect the electrical harness onto the bezel. All vehicles 2. Connect the electrical harness onto the selector lever housing. 3. Align the brake shift interlock override tab into its guide. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5386 4. Install the selector lever bezel onto the selector lever housing. 5. Connect the transmission control (TC) switch electrical connector and install the selector lever knob. 6. Install a new LH selector lever knob screw. ^ tighten to 2 Nm (18 lb-in). 7. Install a new RH selector lever knob screw. ^ Tighten to 2 Nm (18 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5387 8. NOTE: Wood trimmed vehicles have a rubber damper not found on other trim levels. Install a new LH selector lever knob cover. 9. NOTE: Wood trimmed vehicles have a rubber damper not found on other trim levels. Install a new RH selector lever knob cover. 10. Install the console upper trim and the screw. 11. Install the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5388 12. Verify brake shift interlock function. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5389 Shifter A/T: Service and Repair Selector Lever - Column Shift Selector Lever - Column Shift Removal and Installation 1. Remove the lower steering column shroud. 1 Remove the screws and the lower steering column shroud. 2. Remove the upper steering column shroud. 3. Disconnect the electrical connector and the harness from the retaining clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5390 4. Remove the selector lever bolt. ^ To install, tighten to 18 Nm (13 lb-ft). 5. Remove the selector lever. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5391 Shifter A/T: Service and Repair Selector Lever - Floor Shift Selector Lever - Floor Shift Vehicles Equipped With a 6R75 Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5392 Vehicles Equipped With a 6HP26 Transmission Removal Vehicles equipped with a 6R75 transmission 1. Remove the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5393 2. Remove the screw and the console upper trim. 3. NOTE: Selector lever bezel removed for clarity. Disconnect the selector lever cable from the selector lever. 1 Disconnect the selector lever cable from the selector lever arm ball stud. 2 Disconnect the selector lever cable from the selector lever housing. 4. Disconnect the selector lever electrical connector. 5. NOTE: Selector lever bezel removed for clarity. Remove the bolts and lift the selector lever out of the console. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5394 Vehicles equipped with a 6HP26 transmission 6. Remove the selector lever trim plate. 7. NOTE: Using a suitable tool, lift and remove the floor console upper panel from the rear. Remove the floor console upper panel. 8. NOTE: Selector lever bezel removed for clarity. Disconnect the selector lever cable from the selector lever arm ball stud. 9. Remove the center console LH kick panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5395 10. Disconnect the selector lever cable from the selector lever housing. 11. Disconnect the selector lever electrical connector. 12. NOTE: Selector lever bezel removed for clarity. Remove the bolts and lift the selector lever out of the console. Installation Vehicles equipped with a 6R75 transmission 1. NOTE: Selector lever bezel removed for clarity. Install the sector lever into the console. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5396 ^ Tighten to 8 Nm (71 lb-in). 2. Connect the selector lever electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: Selector lever bezel removed for clarity. Connect the selector lever cable onto the selector lever. 1 Connect the selector lever cable onto the selector lever housing. 2 Connect the selector lever cable onto the selector lever arm ball stud. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 4. Install the console upper trim and the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5397 5. Install the PRNDL trim, console tray and cup holder insert. Vehicles equipped with a 6HP26 transmission 6. NOTE: Selector lever bezel removed for clarity. Install the selector lever into the console. ^ Tighten to 8 Nm (71 lb-in). 7. Connect the selector lever electrical connector. 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5398 Connect the selector lever cable onto the selector lever housing. 9. Install the center console LH kick panel. 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: Selector lever bezel removed for clarity. Connect the selector lever cable onto the selector lever arm ball stud. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 11. Install the floor console upper panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 5399 12. Install the selector lever trim plate. All vehicles 13. Adjust the selector lever cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Selector Lever Cable Adjustment 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Place the selector lever in the DRIVE position. 3. If equipped, remove the heat shield. 4. Disconnect the selector lever cable from the manual control lever. 5. NOTE: Make sure the cable moves freely. Unlock the lock tab on the selector lever cable. 6. Place the manual control lever in the DRIVE position. ^ Place the manual control lever in the 1st gear position. ^ Move the manual control lever 3 detents to the DRIVE position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5404 7. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. 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 DRIVE position. Connect the selector lever cable to the manual control lever. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure it is correctly installed. 8. Lock the selector lever cable lock tab. 9. If equipped, install the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5405 10. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1 through 9 must be repeated. ^ Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5408 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the instrument panel lower finish panel. 3. Remove the hood release cable lever. 4. Remove the instrument panel lower reinforcement panel. 5. Remove the steering column lower shroud. 1 Remove the screws and the lower shroud. 6. NOTE: To prevent cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5409 Disconnect the selector lever cable from the steering column. 1 Disconnect the selector lever cable from the selector lever arm ball stud. 2 Carefully lift the locking tab and disconnect the selector lever cable from the steering column bracket. 3 Disconnect the selector lever cable retainer. 7. Push the rubber grommet and selector lever cable down through the floor panel. 8. If equipped, remove the heat shield. 9. NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Move the locking tab up and disconnect the selector lever cable from the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5410 10. Remove the selector lever cable clip to release the selector lever cable from the bracket. 11. Remove the bolts and the selector lever cable bracket from the transmission. Installation 1. Install the selector lever cable bracket and bolts onto the transmission. ^ Tighten to 25 Nm (18 lb-ft). 2. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Install the selector lever cable into the bracket and install the clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5411 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Connect the selector lever cable onto the manual control lever and move the locking tab down. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 4. If equipped, install the heat shield. 5. Push the selector lever cable and rubber grommet up through the floor panel. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5412 cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: To prevent cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Connect the selector lever cable onto the steering column. 1 Connect the selector lever cable retainer. 2 Connect the selector lever cable onto the steering column bracket. 3 Connect the selector lever cable onto the selector lever arm ball stud. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 7. Install the steering column lower shroud. 1 Install the lower shroud. 8. Install the instrument panel lower reinforcement panel. ^ Tighten to 9 Nm (80 lb-in). 9. Install the hood release cable lever. ^ Tighten to 9 Nm (80 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5413 10. Install the instrument panel lower finish panel. 11. Adjust the selector lever cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5414 Shift Cable: Service and Repair Selector Lever Cable and Bracket - Floor Shift Selector Lever Cable and Bracket - Floor Shift Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a 6R75 transmission 2. Remove the PRNDL trim, console tray and cup holder insert. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5415 3. Remove the screw and the console upper trim. 4. NOTE: Selector lever bezel removed for clarity. Disconnect the selector lever cable from the selector lever. 1 Disconnect the selector lever cable from the selector lever arm ball stud. 2 Disconnect the selector lever cable from the selector lever housing. Vehicles equipped with a 6HP26 transmission 5. Remove the selector lever trim plate. 6. NOTE: Using a suitable tool, lift and remove the floor console upper panel from the rear. Remove the floor console upper panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5416 7. NOTE: Selector lever bezel removed for clarity. Disconnect the selector lever cable from the selector lever arm ball stud. 8. Remove the center console LH kick panel. 9. Disconnect the selector lever cable from the selector lever housing. All vehicles 10. Remove the selector lever cable and grommet. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5417 11. If equipped, remove the heat shield. 12. Move the locking tab up and disconnect the selector lever cable from the manual control lever ball stud. 13. Remove the selector lever cable clip to release the selector lever cable from the bracket. 14. Remove the bolts and the selector lever cable bracket from the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5418 Installation All vehicles 1. Install the selector lever cable bracket and bolts onto the transmission. ^ Tighten to 25 Nm (18 lb-ft). 2. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Install the selector lever cable into the bracket and install the clip. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Connect the selector lever cable onto the manual control lever ball stud and move the locking tab down. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5419 4. If equipped, install the heat shield. 5. Install the selector lever cable and grommet. Vehicles equipped with a 6R75 transmission 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: Selector lever bezel removed for clarity. Connect the selector lever cable onto the selector lever. 1 Connect the selector lever cable onto the selector lever housing. 2 Connect the selector lever cable onto the selector lever arm ball stud. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5420 7. Install the console upper trim and the screw. 8. Install the PRNDL trim, console tray and cup holder insert. Vehicles equipped with a 6HP26 transmission 9. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. Connect the selector lever cable onto the selector lever housing. 10. Install the center console LH kick panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5421 11. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. NOTE: Selector lever bezel removed for clarity. Connect the selector lever cable onto the selector lever arm ball stud. ^ Listen for the audible click. ^ Pull back on the selector lever cable to make sure that it is correctly installed. 12. Install the floor console upper panel. 13. Install the selector lever trim plate. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5422 All vehicles 14. Adjust the selector lever cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 6HP26 Automatic Transmission > Page 5448 Torque Converter: Description and Operation 6R75 Automatic Transmission Torque Converter The torque converter is a 3-element unit containing a 3-plate clutch. The clutch can be controlled and engaged in any gear 2 to 6. Calibration parameters may be set to allow lockup in a higher gear only. The clutch is applied by removing fluid pressure from one side of the plate. The torque converter transmits and multiplies torque. The torque converter includes the following 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis Torque Converter: Testing and Inspection Torque Converter Diagnosis 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. Repair all non-transmission related diagnostic trouble codes (DTCs) first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. ^ Carry out Stall Speed Test. ^ Carry out Diagnostic Routines. 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 scan tool. Check for DTCs. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in DRIVE 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. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines/Torque Converter Clutch Operation Concerns 240-242 6. If the vehicle stalls in DRIVE 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. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines/Torque Converter Clutch Operation Concerns 240-242 If the vehicle does not stall in DRIVE, refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shudder. ^ Spark plugs - check for cracks, high resistance or broken insulators ^ Plug wires ^ Fuel injector - filter may be plugged ^ Fuel contamination - engine driveability concerns ^ Exhaust gas recirculation (EGR) valve - valve may let in too much exhaust gas and cause engine to run lean ^ Vacuum leak - engine will not get correct air/fuel mixture ^ Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture ^ Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture ^ Fuel pressure - may be too low ^ Engine mounts - loose/damaged mounts can cause vibration concerns ^ Axle joints - check for vibration 6R75 Automatic Transmission Torque Converter Diagnosis Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5451 Special Tool(s) 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. Repair all non-transmission related DTCs first. - Repair all transmission-related DTCs. - Rerun on-board diagnostics to verify repair. ^ Carry out Stall Speed Test. ^ Carry out Diagnostic Routines. Use the Diagnosis by Symptom to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. Torque Converter Operation Test The Torque Converter Operation Test verifies that the torque converter clutch (TCC) control system and the torque converter are operating correctly. 1. Carry out Quick Test with the scan tool. Refer to Computers and Control Systems. Check for DTCs. 2. Connect a scan tool to the vehicle. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in D position. 4. After normal operating temperature is reached, maintain a constant speed of about 56 km/h (35 mph) in 5th gear for 10 seconds. 5. Release the accelerator pedal and monitor the scan tool TP voltage to approximately 1.25 volts or 25 percent throttle. 6. Monitor the TCC and engine speed PID. The TCC should release and engine rpms should increase before the 5-4 shift occurs. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as TCC shudder. ^ Spark plugs - check for cracks, high resistance or broken insulators ^ Plug wires ^ Fuel injector - filter may be plugged ^ Fuel contamination - engine driveability concerns ^ Exhaust gas recirculation (EGR) valve - valve may let in too much exhaust gas and cause engine to run lean ^ Vacuum leak - engine will not get correct air/fuel mixture ^ Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture ^ Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture ^ Fuel pressure - may be too low ^ Engine mounts - loose/damaged mounts can cause vibration concerns ^ Axle joints - check for vibration Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5452 Torque Converter: Testing and Inspection Torque Converter 6HP26 Automatic Transmission Torque Converter 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: ^ A torque converter malfunction has been determined based on complete diagnostic procedures. ^ Converter stud or studs, impeller hub or bushing are damaged. ^ Discoloration (due to overheating). ^ Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major metallic failure. - Multiple clutches or clutch plate failures. - Sufficient component wear which results in metallic contamination. - Internal torque converter contamination present. 6R75 Automatic Transmission Torque Converter 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: ^ A torque converter malfunction has been determined based on complete diagnostic procedures. ^ Converter rivets, impeller hub or bushing are damaged. ^ Discoloration (due to overheating). ^ Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major metallic failure. - Multiple clutches or clutch plate failures. - Sufficient component wear which results in metallic contamination. - Internal torque converter contamination present. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5453 Torque Converter: Testing and Inspection Stall Speed Stall Speed Stall Speed Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5454 Torque Converter: Testing and Inspection Torque Converter Contamination Inspection 6HP26 Automatic Transmission Torque Converter Contamination Inspection Material CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission, damage will occur. Use only clean automatic transmission fluid designated for the transmission and converter being serviced. 1. If a new or remanufactured torque converter is not being installed, the following steps must be completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the fluid. 3. NOTE: The factory fill fluid is clear, the exchange fluid will be red. Observe the color and odor of the fluid. The fluid should be clear or red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure. 4. Examine the stain on the tissue for evidence of particles (specks of any kind). Examine the fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the fluid, a new torque converter must be installed. 5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter. 6. Add 1.9 liter (2 quarts) of clean automatic transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the fluid. 6R75 Automatic Transmission Torque Converter Contamination Inspection Material CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission, damage will occur. Use only clean automatic transmission fluid designated for the transmission and converter being serviced. 1. If a new or remanufactured torque converter is not being installed, the following steps must be completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the fluid. 3. Observe the color and odor of the fluid. The fluid should be red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure. 4. Examine the stain on the tissue for evidence of particles (specks of any kind). Examine the fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the fluid, a new torque converter must be installed. 5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter. 6. Add 1.9L (2 qt) of clean automatic transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications > Page 5480 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Inspection and Verification CAUTION: When internal wear or damage occurs in the transmission, metal particles, clutch plate material and band material can travel into the torque converter, the fluid cooler tubes, the in-tank transmission fluid cooler and the auxiliary transmission fluid cooler, if so equipped. These contaminants are a major cause of recurring transmission concerns. To prevent future concerns, remove these contaminants from the cooling system before placing the transmission back into use. 1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and system leaks. Repair as necessary. ^ Install a new or remanufactured radiator when fluid is found leaking from the in-tank transmission fluid cooler. ^ Install a new O-ring when transmission fluid is found leaking between the radiator transmission oil cooler and the transmission oil cooler fitting (not the cooler line into the fitting). ^ Install a new auxiliary transmission fluid cooler if there is leakage from the fluid cooler. 2. If the fault is not visually evident, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5483 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5484 Transmission Cooler: Component Tests and General Diagnostics 6HP26 Automatic Transmission Transmission Fluid Cooler CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque converter/oil cooler cleaner. NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the normal cleaning and inspection procedures during disassembly and reassembly, will keep contaminants from entering the transmission, causing a repeat repair. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into use. 6R75 Automatic Transmission Transmission Fluid Cooler CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque converter/oil cooler cleaner. NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the normal cleaning and inspection procedures during disassembly and reassembly, will keep contaminants from entering the transmission, causing a repeat repair. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into use. Transmission Fluid Cooler Leaks at Radiator Transmission Fluid Cooler Leaks at Radiator Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the fluid cooler fitting. The in-tank transmission fluid cooler is not serviceable. If installation of a new transmission fluid cooler is required, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures 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 leaks 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 fluid cooler 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. 6R75 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 leaks 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5487 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5488 Transmission Cooler: Removal and Replacement Auxiliary Transmission Fluid Cooler Removal 1. Remove the upper radiator cover. 1 Remove the fasteners. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5489 2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamp. 3. Disconnect the auxiliary transmission fluid cooler inlet hose from the cooler. 4. With the vehicle in NEUTRAL, position it on a hoist. 5. Move the flexible air deflector aside, then remove and discard the auxiliary transmission fluid cooler outlet hose clamp. 6. Disconnect the auxiliary transmission fluid cooler outlet hose from the cooler. 7. Remove the auxiliary transmission fluid cooler. Installation 1. Install the auxiliary transmission fluid cooler. 2. Connect the auxiliary transmission fluid cooler outlet hose to the cooler. 3. Install a new auxiliary transmission fluid cooler outlet hose clamp, then move the flexible air deflector back into place. 4. Connect the auxiliary transmission fluid cooler inlet hose to the cooler. 5. Install a new auxiliary transmission fluid cooler inlet hose clamp. 6. Install the upper radiator cover. 1 Install the fasteners. 7. Fill the transmission with fluid and verify correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5516 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5519 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > 6HP26 Automatic Transmission > Page 5545 Air Pressure Test Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Valve Body: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5596 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM Valve Body: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5601 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5602 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5603 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Valve Body: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 5609 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Valve Body: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5614 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5615 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5616 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5617 Check Ball Location Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5618 Valve Body: Diagrams Mechatronic Assembly Exploded Views Mechatronic Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5619 Mechatronic Upper Half Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5620 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5621 Mechatronic Lower Half Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5622 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5623 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement 6HP26 Automatic Transmission Main Control Valve Body Special Tool(s) 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 the transmission fluid pan and allow the fluid to drain. 4. Remove the fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5626 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5627 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. NOTE: During removal of the mechatronic assembly, the thermal bypass valve, pump adapter seal and one or more center support seals may become dislodged. Save these components for reuse during assembly. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly. Installation 1. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time. Verify the 4 rubber feed tubes for the center support are in place. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5628 2. Verify the thermal bypass valve is in the case. 3. Verify the rubber adapter is in place. 4. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit. Position the mechatronic assembly in place and loosely install the 10 bolts. 1 Align the manual valve and control lever linkage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5629 5. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 8 Nm (71 lb-in). 6. Install new O-rings seals on the outer shell of the bulkhead electrical connector.! 7. 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. 8. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5630 9. Install a new transmission fluid filter. 10. Install the fluid pan gasket. 11. Install the fluid pan and bolts. ^ Tighten to 12 Nm (9 lb-ft). 12. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5631 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. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical connector. 14. 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. 15. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 16. With the special tool connected, the engine idling (550-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level. 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. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5632 18. Install the fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). 6R75 Automatic Transmission Mechatronic Assembly Removal NOTE: If a new or the existing mechatronic assembly is installed, the transmission control module (TCM) will need to be reflashed to the latest level calibration available. 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 the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5633 4. Remove the transmission fluid pan and allow the fluid to drain. 5. Remove the fluid pan gasket. 6. Remove and discard the transmission fluid filter. 7. Pull the release tab and pull down on the bulkhead connector retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5634 8. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. With the release tab down, pull the outer shell of the bulkhead electrical connector out of the TCM. 9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Pull the bulkhead electrical connector out of the transmission. 10. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly. Installation 1. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5635 during removal and should be installed into the transmission case at this time. Verify the 4 rubber feed tubes for the center support are in place. 1 Black feed tube. 2 Green feed tube. 3 Blue feed tube. 2. Verify the rubber adapter is in place. 3. Verify the thermal bypass valve is in the case. 4. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Position the mechatronic assembly in place and loosely install the 11 bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5636 1 Align the manual valve and control lever linkage. 5. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-in). 6. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the mechatronic unit. With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM. 7. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked. 8. Install a new transmission fluid filter. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5637 9. NOTE: The fluid pan gasket can be reused if not damaged. Install the transmission fluid pan gasket if required. 10. Install the fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 11. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 12. Using the refill procedure, fill and check the transmission fluid. 13. If a new or the existing mechatronic assembly is installed, the TCM will need to be reflashed to the latest level calibration available. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5638 Valve Body: Overhaul Mechatronic Assembly Mechatronic Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5639 Mechatronic Upper Half Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5640 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5641 Mechatronic Lower Half Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5642 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5643 Check Ball Location Disassembly CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). An electrostatic discharge may occur and may cause damage to the TCM/Mechatronic assembly. NOTE: Make an identifying mark on each solenoid and the corresponding bore for correct assembly. NOTE: Solenoids may visually appear the same but their designs/functions are different. Caution must be taken not to assemble the mechatronics assembly incorrectly. Incorrect solenoid installation will result in poor transmission shift quality. NOTE: Note where the 8 check balls, 6 solenoid dampers, 2 internal valves and springs and 2 internal filters are located for reassembly. Mechatronic assembly upper half Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5644 1. Make an identifying mark on each solenoid and the corresponding bore for correct assembly. 2. Remove the 6 long bolts from the TCM unit. 3. Carefully separate the TCM from the mechatronic assembly. 4. Remove 19 short bolts from the mechatronic assembly. 5. Separate the lower half of the mechatronic assembly from the upper half of the mechatronic assembly. 6. Remove and discard the separator plate. 7. Remove from the mechatronic assembly the clips, caps, valves and spring from each bore. Note the location and order for reassembly. Refer to the preceding exploded views. 8. Remove from the mechatronic assembly the transmission control valves, check balls and filter screens. Note the location and order for reassembly. Refer to the preceding exploded views. 9. Using clean mineral spirits, clean the upper half of the mechatronic assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5645 Mechatronic assembly lower half 10. Remove the 8 solenoid bracket bolts and the solenoid bracket. 11. Remove the solenoids. 12. Remove from the mechatronic assembly the clips, caps, valves and spring from each bore. Note the location and order for reassembly. Refer to the preceding exploded views. 13. Using clean mineral spirits, clean the lower half of the mechatronic assembly. Assembly CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. An electrostatic discharge may occur and may cause damage to the TCM/Mechatronic assembly. Mechatronic assembly upper half 1. NOTE: Many components and surfaces in the mechatronic valve body are precision machined. Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary damage to machined surfaces. Install the clips, caps, valves and spring into each bore. Refer to the preceding exploded views. Mechatronic assembly lower half 2. NOTE: Many components and surfaces in the mechatronic valve body are precision machined. Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary damage to machined surfaces. Install the clips, caps, valves and spring into each bore. 3. NOTE: Lubricate the O-ring seals of the solenoids with clean automatic transmission fluid when installing them into the valve body. Install the solenoids into their correct bores as indicated during disassembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5646 4. Install the solenoid bracket and the 8 bolts. ^ Tighten to 6 Nm (53 lb-in). 5. Install into the mechatronic assembly the transmission control valves, check balls and filter screens. Refer to the preceding exploded views. 6. Install a new separator plate. 7. Assemble the lower half and the upper half of the mechatronic assembly. 8. Install the 19 short bolts into the mechatronic assembly. Tighten the bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-in). 9. Carefully install the TCM onto the mechatronic assembly. 10. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5647 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5653 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential Differential Output Shaft Bearing: Service and Repair Rear Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Special Tool(s) Material NOTE: The stub shaft seals must be replaced whenever the halfshafts are removed. 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 and discard 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 and discard the bearing and the stub shaft pilot bearing oil seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5659 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 seal without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the special tools. 6. Install the stub shaft pilot bearing into the rear axle housing bore. 7. NOTE: Do not disassemble the new oil seal. NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components. Install the new seal onto a suitable installer. 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. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between the stub shaft oil seal and the differential housing, the stub shaft seal is not seated correctly. Remove the stub shaft oil seal and install a new stub shaft oil seal. Make sure the stub shaft oil seal is correctly seated in the differential housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5660 10. CAUTION: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seal journal with fine crocus cloth, if required. Install the halfshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5661 Differential Output Shaft Bearing: Service and Repair Front Drive Axle and Differential Stub Shaft Pilot Bearing and Seal Special Tool(s) Removal NOTE: Install a new stub shaft seal whenever a halfshaft is removed. 1. Remove the front drive halfshafts. 2. Using the special tools, remove the intermediate shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5662 3. Remove and discard the intermediate shaft circlip and O-ring. 4. Using a suitable seal remover, remove and discard the stub shaft pilot bearing oil seal. 5. Using the special tools, remove and discard the stub shaft pilot bearing. Installation 1. Position the stub shaft pilot bearing in the axle tube or differential housing bore and using the special tool, install the bearing. 2. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft bearing oil seal flush in the housing using the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5663 3. Install a new O-ring and new circlips on the intermediate shaft ends. 4. Insert the intermediate shaft and engage the circlip with the differential side gear. 5. Install the front drive halfshafts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential Pinion Flange: Service and Repair Rear Drive Axle/Differential Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Material 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 LH rear quarter trim panel. Failure to do so can Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5668 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. NOTE: If equipped, turn the air suspension switch to the OFF position. With the vehicle in NEUTRAL, position the vehicle on a hoist. 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 (lb-in) 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. 8. Using the special tool, remove the drive pinion flange. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5669 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5670 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 (lb-in) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. ^ Refer to the torque specification for used pinion bearings. 8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5671 12. If equipped with air suspension, reactivate the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5672 Pinion Flange: Service and Repair Front Drive Axle and Differential Drive Pinion Seal Drive Pinion Seal Special Tool(s) 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. Universal Joint Flange Universal Joint Flange Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5673 Special Tool(s) Material Removal CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the preload during assembly. 1. Position the vehicle on a hoist. 2. 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. 3. Index-mark the front driveshaft to the axle universal joint flange. 4. CAUTION: Do not allow the driveshaft to hang unsupported. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5674 Disconnect and support the front driveshaft. ^ Remove and discard the 6 bolts and 3 washers. ^ Carefully disconnect and support the front driveshaft. 5. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation. 6. CAUTION: After removing the pinion nut, discard it. Use a new pinion nut for installation. Install the special tool and remove the pinion nut. 7. Index-mark the axle universal joint flange to the pinion stem. 8. Using the special tool, separate the axle universal joint flange from the pinion gear. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5675 9. Remove the flange. 10. 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. 11. 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. 3. NOTE: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. 4. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool and tighten the pinion nut. Refer to the torque specifications for used bearings. ^ Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch/pound) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to the specification. If Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Rear Drive Axle/Differential > Page 5676 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. 6. Inspect and, if necessary, fill the differential. ^ Use rear axle lubricant. 7. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential Seals and Gaskets: Service and Repair Rear Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Special Tool(s) Material NOTE: The stub shaft seals must be replaced whenever the halfshafts are removed. 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 and discard 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 and discard the bearing and the stub shaft pilot bearing oil seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5681 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 seal without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the special tools. 6. Install the stub shaft pilot bearing into the rear axle housing bore. 7. NOTE: Do not disassemble the new oil seal. NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components. Install the new seal onto a suitable installer. 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. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between the stub shaft oil seal and the differential housing, the stub shaft seal is not seated correctly. Remove the stub shaft oil seal and install a new stub shaft oil seal. Make sure the stub shaft oil seal is correctly seated in the differential housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5682 10. CAUTION: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seal journal with fine crocus cloth, if required. Install the halfshaft. Drive Pinion Flange and Drive Pinion Seal Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5683 Material 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 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 and vehicle damage. NOTE: If equipped, turn the air suspension switch to the OFF position. With the vehicle in NEUTRAL, position the vehicle on a hoist. 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 (lb-in) 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5684 7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during installation. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5685 3. Lubricate the drive pinion flange splines with rear axle lubricant. 4. NOTE: Disregard the index marks if installing a new drive pinion flange. Position the drive pinion flange. 5. Using the 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5686 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 (lb-in) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. ^ Refer to the torque specification for used pinion bearings. 8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5687 Seals and Gaskets: Service and Repair Front Drive Axle and Differential Drive Pinion Seal Drive Pinion Seal Special Tool(s) 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. Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5688 Special Tool(s) Removal NOTE: Install a new stub shaft seal whenever a halfshaft is removed. 1. Remove the front drive halfshafts. 2. Using the special tools, remove the intermediate shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5689 3. Remove and discard the intermediate shaft circlip and O-ring. 4. Using a suitable seal remover, remove and discard the stub shaft pilot bearing oil seal. 5. Using the special tools, remove and discard the stub shaft pilot bearing. Installation 1. Position the stub shaft pilot bearing in the axle tube or differential housing bore and using the special tool, install the bearing. 2. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft bearing oil seal flush in the housing using the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Drive Axle/Differential > Page 5690 3. Install a new O-ring and new circlips on the intermediate shaft ends. 4. Insert the intermediate shaft and engage the circlip with the differential side gear. 5. Install the front drive halfshafts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications Axle Shaft Assembly: Mechanical Specifications General Specifications Torque Specifications General Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5696 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5697 Materials Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 New halfshaft components are available as follows: ^ A repair kit includes the boots, clamps, snap ring, retaining ring and grease. ^ A new inboard constant velocity (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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 5700 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement Axle Shaft Assembly: Removal and Replacement Front Drive Halfshafts Halfshaft Special Tool(s) Removal and Installation CAUTION: Whenever a halfshaft is removed, a new circlip and stub shaft pilot bearing seal must be installed. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disable the air suspension system. 3. Remove the dust cap. 4. Remove and discard the axle nut. ^ To install, tighten to 27 Nm (20 lb-ft). 5. Remove the vacuum/vent line at the vacuum/vent port of the integrated wheel end (IWE) disconnect. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5703 6. Remove the 3 IWE retaining bolts to the steering knuckle. ^ To install, tighten to 12 Nm (9 lb-ft). 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 lb-ft). 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 lb-ft). 9. CAUTION: Do not damage the hub seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5704 NOTE: Allow the steering knuckle to swing outboard while keeping the constant velocity (CV) shaft pushed inboard. Once clearance is available, remove the CV shaft joint outboard end and IWE disconnect from the steering knuckle hub bearing. 10. Remove the IWE disconnect from the outboard CV joint housing. 11. Using the special tools, remove the halfshaft from the differential and the intermediate shaft. 12. Remove and discard the circlip and the stub shaft seal. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5705 Special Tool(s) Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5706 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, position it on a hoist. 2. 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 lb-ft). 3. Using a suitable hub puller, separate the halfshaft from the knuckle. 4. Remove the brake disc rotor. 5. Remove the upper trailing arm bolt. ^ To install, tighten to 250 Nm (184 lb-ft). 6. Remove the upper trailing arm-to-wheel knuckle nut. ^ To install, tighten to 103 Nm (76 lb-ft). 7. Using the special tool, separate the upper arm from the wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5707 8. Remove the stabilizer bar link nut. ^ To install, tighten to 63 Nm (46 lb-ft). 9. Remove the toe link-to-knuckle bolt. ^ To install, tighten 225 Nm (166 lb-ft). 10. Disconnect the anti-lock brake sensor at the connector and open the wire retaining clips. 11. Compress the spring, depress the retaining tabs and detach the parking brake cable from the wheel knuckle. 12. Remove the 2 lower trailing arm-to-wheel knuckle bolts. ^ To install, tighten to 103 Nm (76 lb-ft). 13. Remove the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 14. Using the special tool, separate the lower ball joint from the wheel knuckle. 15. Rotating the top of the knuckle assembly outboard, remove the knuckle assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5708 16. 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. 17. Remove the halfshaft assembly from the vehicle. 18. Remove and discard the halfshaft retainer circlip. 19. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5709 Axle Shaft Assembly: Overhaul Front Drive Halfshafts Halfshaft Special Tool(s) 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 constant velocity (CV) joint housing. 4. Remove the retaining ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5710 5. Remove the inboard CV joint housing. 6. Index-mark the inner race and ball cage. 7. Remove the 6 balls. 8. Remove the snap ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5711 9. Remove the inner race and the ball cage. 10. Remove the inboard boot. 11. Remove the boot clamps. 12. Remove the outboard boot. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5712 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 CV joint grease or equivalent provided in the boot kit. 2 Spread any remaining grease from the kit evenly inside the boot. 3. Install the outboard boot. 1 Clean the boot mounting surface. 2 Seat the boot in the joint boot groove. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5713 4. Position the boot clamps. 5. NOTE: Tighten the through-bolt until the tool is in the closed position. Using the special tool, install the 2 boot clamps. 6. Position the boot clamp on the shaft. 7. Position the inboard boot on the shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5714 8. Position the ball cage on the shaft with the tapered end facing the boot. 9. NOTE: Align the index marks. Position the inner race on the shaft with the counterbored end facing the boot. 10. Install the snap ring. 11. Lubricate and position the 6 balls. ^ Use CV joint grease or equivalent provided in the boot kit. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5715 12. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease. ^ Use CV joint grease or equivalent provided in the boot kit. 13. Position the boot clamp on the inboard CV joint housing. 14. Position the inboard CV joint housing on the ball and race assembly. 15. Install the retaining ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5716 16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove. 17. Set the halfshaft assembled length to specification. 18. CAUTION: Do not damage the boot. Insert a dull screwdriver blade under the boot to release the pressure. 19. NOTE: Tighten the through-bolt until the tool is in the closed position. Using the special tool, install the 2 boot clamps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5717 20. NOTE: Maintain a clean work surface. Compress the integrated wheel end (IWE) disconnect on the bench to collapse the vacuum chamber. 21. While the IWE disconnect is collapsed, install a vacuum cap on the vacuum port. 22. 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 IWE disconnect on the outer CV joint housing. 23. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. Install the halfshaft in the vehicle. Rear Drive Halfshafts Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5718 Halfshaft Joint Special Tool(s) Material Disassembly 1. Remove the halfshaft assembly from the vehicle. 2. For the inboard CV joint, carry out the following: 1 Remove and discard the boot clamps. ^ 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5719 4. Using a suitable 3-jaw puller, remove the CV joint. 5. Remove and discard the tri-lobe insert and the boot. 6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or installed from the inboard CV joint side of the shaft. For the outboard CV joint, carry out the following: 1 Remove and discard the boot clamps. 2 Remove and discard the boot. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5720 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5721 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5722 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. 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 overexpand 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 (2007)) 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 (2007)) 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 5731 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 (2007)) 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 5732 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 (2007)) 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 5733 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 (2007)) 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 5734 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 (2007)) 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 (2007)) 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 5740 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 (2007)) 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 5741 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 (2007)) 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 5742 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 (2007)) 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 5743 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 (2007)) 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 5744 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 (2007)) 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 5745 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 (2007)) 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 5746 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 (2007)) 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 5747 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 (2007)) 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 5748 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 (2007)) 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 5749 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 (2007)) 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 5750 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 (2007)) 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 5751 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 (2007)) 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 5752 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5757 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. Disconnect the wheel speed sensor electrical connector. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the wheel speed sensor harness bolt and detach the harness from the retainers. ^ To install, tighten to 12 Nm (9 lb-ft). 4. 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 brake caliper and anchor plate assembly aside. ^ Support the brake caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the halfshaft nut dust cap. 7. Remove and discard the halfshaft nut. ^ To install, tighten to 27 Nm (20 lb-ft). 8. Remove the 4 wheel bearing and wheel hub bolts and the wheel hub. ^ To install, tighten to 185 Nm (136 lb-ft). 9. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 18 Nm (13 lb-ft). 10. CAUTION: If the original wheel bearing and wheel hub is being installed, install a new wheel hub O-ring seal. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5758 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. ^ To install, tighten to 300 Nm (221 lb-ft). 3. Using a suitable hub puller, separate the outboard CV joint from the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5759 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 190 Nm (140 lb-ft). 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 wheel bearing and wheel hub bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake disc shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 lb-ft). 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. ^ To install, tighten to 18 Nm (13 lb-ft). 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Front Front Axle nut....................................................................................................................................... ......................................................... 27 Nm (20 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 5765 Axle Nut: Specifications Rear Rear axle Nut ....................................................................................................................................... .................................................... 300 Nm (221 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 5769 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Service and Repair > Page 5773 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams Drive/Propeller Shaft: Diagrams Front, Expedition and Navigator Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 5778 Rear - Navigator Four Wheel Drive (4WD), Expedition 4WD and Rear Wheel Drive (RWD) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 5779 Rear, Navigator RWD Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. Disable the air suspension system. 2. With the vehicle in NEUTRAL, position the vehicle on a hoist. 3. Index-mark the front flange to the pinion flange. 4. Index-mark the rear flange to the transfer case flange. 5. Remove and discard the 6 rear flange-to-transfer case flange bolts. Retain the 3 washers. ^ To install, tighten to 55 Nm (41 lb-ft). 6. Remove and discard the 6 front flange-to-pinion flange bolts. Retain the 2 washers. ^ To install, tighten to 55 Nm (41 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5782 7. Remove and discard the 4 stabilizer bracket nuts and allow the stabilizer bar to swing downward. ^ To install, tighten to 55 Nm (41 lb-ft). 8. Remove the front driveshaft from the vehicle. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5783 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Expedition Driveshaft - Rear, Expedition Material Removal and Installation 1. Disable the air suspension system. 2. With the vehicle in NEUTRAL, position the vehicle on a hoist. 3. Index-mark the driveshaft flange to the rear axle pinion flange. 4. Remove the 4 driveshaft flange bolts. ^ To install, tighten to 103 Nm (76 lb-ft). 5. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5784 6. 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. 7. 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 103 Nm (76 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5785 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Navigator Driveshaft - Rear, Navigator Material Removal and Installation All vehicles 1. Disable the air suspension system. 2. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 3. Index-mark the driveshaft flange to the pinion flange. 4. Index-mark the driveshaft slip yoke to the transmission extension housing. 5. Remove and discard the 4 driveshaft flange bolts. 6. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5786 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 pinion flange. 7. NOTE: Do not rotate the driveshaft when removing the slip yoke from the transmission output shaft. Remove the driveshaft. ^ Mark the transmission output shaft to the transmission extension housing after removing the driveshaft. Rear wheel drive (RWD) vehicles 8. Index-mark the driveshaft for correct alignment during installation. 9. Remove and discard the 3 flex-coupler-to-flange nuts and the 3 flex-coupler-to-flange bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5787 10. Remove and discard the 4 driveshaft flange bolts. 11. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool, disconnect the driveshaft flange from the pinion flange. 12. Remove the 2 driveshaft center bearing bolts, then remove the driveshaft. ^ Discard the driveshaft center bearing bolts. Installation 4WD vehicles 1. Align all the index marks and install the driveshaft slip yoke into the transmission extension housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5788 2. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the driveshaft flange seat squarely on the pinion flange pilot, tighten the driveshaft flange bolts evenly in a cross pattern. Align the index marks and install the driveshaft flange and the driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). RWD vehicles 3. CAUTION: If new driveshaft center bearing bolts are not available, coat the threads of the original driveshaft center bearing bolts with Threadlock and Sealer. Position the driveshaft center bearing and hand-tighten the 2 new driveshaft center bearing bolts until the driveshaft is mounted to the flanges. ^ Tighten to 48 Nm (35 lb-ft). 4. CAUTION: If new flex-coupler-to-flange bolts and flex-coupler-to-flange nuts are not available, coat the threads of the original flex-coupler-to-flange bolts with Threadlock and Sealer. Install the 3 new flex-coupler-to-flange bolts and the 3 new flex-coupler-to-flange nuts. ^ Tighten the nuts to 150 Nm (111 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5789 5. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the driveshaft flange seat squarely on the pinion flange pilot, tighten the driveshaft flange bolts evenly in a cross pattern. Install the 4 new driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5790 Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Material Removal and Installation 1. Remove the driveshaft. 2. Index-mark the driveshaft to the center bearing for correct alignment during installation. 3. Disconnect the slip yoke boot. 4. Separate the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5791 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Universal Joints The universal joint (U-joint) connects to the drive axle of the driveshaft and allows for up and down movement of the axle. The U-joint is lubricated for the life of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5795 Universal Joint: Service and Repair Driveshaft Universal Joint - Single Cardan Special Tool(s) 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-mark the driveshaft components relative to the driveshaft tube. Make sure all components are reassembled in the same relationship to maintain correct balance. Index the driveshaft and driveshaft components. 4. Position the special tool in a vise. 5. Remove the snap rings from the universal joint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5796 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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 5797 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. Check the universal joint for freedom of movement. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5801 Flex Plate: Service and Repair Flexplate Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5802 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 DTCs may be set during PTO operation. Prior to an Inspection/Maintenance test, operate the vehicle 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 5821 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 5826 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5831 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5832 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5833 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 5839 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 5844 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5849 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5850 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5851 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5856 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5857 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5864 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5865 orientation. 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 (2007)) 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 5866 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5867 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5868 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5869 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5870 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5871 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5872 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5873 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5874 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5875 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5876 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5877 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5878 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5879 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5880 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5881 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5886 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5887 orientation. 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 (2007)) 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 5888 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5889 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5890 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5891 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5892 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5893 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5894 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5895 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5896 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5897 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5898 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5899 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5900 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5901 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5902 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5907 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5908 orientation. 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 (2007)) 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 5909 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5910 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5911 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5912 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5913 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5914 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5915 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5916 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5917 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5918 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5919 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5920 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5921 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5922 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5923 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5929 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5930 orientation. 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 (2007)) 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 5931 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5932 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5933 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5934 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5935 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5936 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5937 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5938 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5939 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5940 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5941 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5942 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5943 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5944 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5945 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5946 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5947 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5950 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5955 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5956 orientation. 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 (2007)) 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 5957 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5958 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5959 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5960 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5961 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5962 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5963 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5964 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5965 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5966 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5967 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5968 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5969 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5970 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5971 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5976 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5977 orientation. 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 (2007)) 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 5978 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5979 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5980 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5981 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5982 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5983 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5984 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5985 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5986 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5987 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5988 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5989 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5990 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5991 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 5992 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6018 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6023 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6024 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6029 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6030 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling Special Tool(s) Material 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 lb-ft). 2. Clean the area around the fill plug. Remove the fill plug. 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 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6034 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6039 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6040 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Transfer Case Rear Output Shaft Seal Special Tool(s) Removal 1. 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 (2007)) 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 - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6048 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6056 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6057 orientation. 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 (2007)) 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 6058 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6059 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6060 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6061 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6062 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6063 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6064 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6065 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6066 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6067 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6068 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6069 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6070 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6072 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6076 C2139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift 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 (2007)) 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 - Floor Shift > Page 6079 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Set the parking brake. 2. Remove the steering column shrouds. 3. Turn the ignition to the accessory position and apply the brake or actuate the brake shift interlock actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Floor Shift > Page 6080 8. NOTE: During installation, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6085 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6086 orientation. 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 (2007)) 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 6087 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6088 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6089 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6090 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6091 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6092 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6093 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6094 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6095 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6096 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6097 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6098 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6099 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6100 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6101 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6106 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6107 orientation. 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 (2007)) 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 6108 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6109 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6110 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6111 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6112 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6113 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6114 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6115 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6116 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6117 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6118 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6119 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6120 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6121 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6122 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 6138 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: Customer Interest Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 6143 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6148 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6149 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6150 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Control Module: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 6156 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare Control Module: All Technical Service Bulletins Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare TSB 07-8-11 04/30/07 HARSH 1-2 AND/OR 2-1 SHIFTS, TIP-IN HESITATION OR SURGE, AND/OR LONG ENGAGEMENT TIME FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-4-8 to update the vehicle application. ISSUE Some 2007 Expedition and Navigator vehicles may exhibit a harsh tip-in from low speeds below 7 MPH (11 Km/h), typically when still in 1st gear such as when in a traffic jam. Additionally some 2007 Expedition vehicles may exhibit a harsh 1-2 shift and/or 2-1 downshift, 1-2 shift flare, and/or long engagement time. ACTION Reprogram the powertrain control module (PCM) and transmission control module (TCM) to the latest calibration using IDS release 47.6 or higher and 48.1 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at the website. SERVICE PROCEDURE Navigator Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM calibration using IDS release 47.6 or higher and 48.1 and higher. Expedition Procedure 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the PCM and 1CM calibration using IDS release 47.6 or higher and 48.1 and higher. Since the 1CM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS (1) Open Toolbox. (2) Choose Powertrain. (3) Choose reset KAM. (4) Then choose TCM. b. Using PDS (1) Choose "All Tests and Calibrations". (2) Scroll down the menu and choose "Reset TCM KAM" NOTE NOTE: FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-8-11 > Apr > 07 > Engine Control - Harsh 1-2/2-1 Shifts/1-2 Shift Flare > Page 6161 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a COMPLETE STOP and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-d) a total of five (5) times WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070811A 2007 Navigator: Check 0.4 Hr. DTCs And Reprogram The PCM. (Do Not Use With 12650D) 070811B 2007 Expedition: Check 0.9 Hr. DTCs And Reprogram The PCM and TCM, Includes Time To Clear KAM, Check Fluid Level, And Update Transmission Adaptive Strategy (Do Not Use with 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6166 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6167 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 6168 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6173 Control Module: Diagrams C281A C281B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 6174 Control Module: Service and Repair Four Wheel Drive (4WD) Control Module Removal and Installation 1. Remove the RH-side cowl side panel cover to gain access. 2. Remove the 2 screws. 3. Disconnect the electrical connectors. 4. Remove the 4WD control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6181 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6182 orientation. 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 (2007)) 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 6183 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6184 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6185 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6186 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6187 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6188 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6189 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6190 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6191 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6192 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6193 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6194 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6195 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6196 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6197 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6198 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6203 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6204 orientation. 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 (2007)) 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 6205 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6206 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6207 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6208 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6209 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6210 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6211 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6212 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6213 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6214 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6215 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6216 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6217 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6218 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6219 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6224 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6225 orientation. 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 (2007)) 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 6226 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6227 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6228 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6229 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6230 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6231 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6232 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6233 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6234 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6235 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6236 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6237 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6238 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6239 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6240 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6246 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6247 orientation. 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 (2007)) 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 6248 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6249 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6250 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6251 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6252 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6253 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6254 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6255 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6256 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6257 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6258 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6259 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6260 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6261 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6262 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6263 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6264 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is not replaceable. If a new TC switch is required, install a new transmission selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 6267 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a new selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6272 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6273 orientation. 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 (2007)) 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 6274 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6275 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6276 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6277 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6278 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6279 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6280 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6281 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6282 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6283 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6284 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6285 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6286 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6287 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6288 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6293 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6294 orientation. 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 (2007)) 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 6295 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6296 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6297 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6298 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6299 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6300 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6301 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6302 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6303 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6304 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6305 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6306 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6307 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6308 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6309 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 orientation. 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 (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Transmission Temperature 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 6335 Four Wheel Drive Selector Switch: Diagrams C284 C2071 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 6341 View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 6342 C3073 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 6343 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 6344 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6353 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6354 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6360 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6361 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6362 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6363 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6364 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module 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 air cleaner outlet pipe from the air cleaner cover. ^ to install, tighten the clamps to 4 Nm (35 inch lbs.) 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the 3 hydraulic control unit (HCU) bracket bolts. ^ To install, tighten to 20 Nm (15 ft. lbs.) 6. Disconnect the anti-lock brake system (ABS) module electrical connector. 7. Remove the 4 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.) 8. To install, reverse the removal procedure. ^ If installing a new ABS module, program the module. For additional information, refer to Information Bus (Module Configuration). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6368 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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 the master cylinder brake tube fittings to 25 Nm (18 ft. lbs.) - tighten the remaining brake tube fittings to 20 Nm (15 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 (2007)) 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 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Page 6372 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: Customer Interest ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 6381 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6386 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6387 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 6393 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6398 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6399 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 6400 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 3 Nm (27 inch lbs.) 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 6404 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 6405 Traction Control Switch: Service and Repair Stability/Traction Control Switch - Expedition Stability/Traction Control Switch - Expedition Removal and Installation 1. Remove the lower instrument cluster center finish panel. 2. Remove the upper instrument cluster center finish panel. ^ Disconnect the electrical connectors. 3. Depress the 4 tabs and remove the traction control switch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 6406 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6415 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6416 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 6421 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6427 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6428 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 6433 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left/Right Front View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 6436 Wheel Speed Sensor: Locations Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 6437 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6440 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6441 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6442 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) 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 6445 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6454 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6455 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6461 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6462 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 6463 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 6464 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6469 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6470 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6471 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6472 Brake Bleeding: Service and Repair Gravity Gravity 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. ^ Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6473 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6474 Brake Bleeding: Service and Repair Manual Manual 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6475 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6476 Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6477 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6478 with pressure bleeding equipment. NOTE: This procedure must be performed if the anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Gravity Gravity Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6479 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6480 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6481 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 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6482 NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough clean, 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 clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified 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. 8. Fill the brake master cylinder reservoir with clean, specified brake fluid and install the brake master cylinder filler cap. Master Cylinder, Bench Master Cylinder, Bench Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6483 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6484 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Brake Pedal Assy: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 6493 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Brake Pedal Assy: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 6499 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 6500 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Brake Pedal and Bracket 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 6501 Disconnect the battery negative cable. For additional information, refer to Battery. 2. If equipped, disconnect the accelerator pedal-to-brake pedal cable from the adjustable brake pedal motor. All vehicles 3. CAUTION: Always remove the stoplamp switch with the brake pedal secured to the brake booster push rod and with the brake pedal in the at-rest position. Do not press or pull on the brake pedal when removing the switch or damage to the switch can occur. CAUTION: The stoplamp switch must be removed prior to removing the brake pedal and bracket, brake booster and associated mounting fasteners or damage to the switch can occur. Disconnect the electrical connector and turn the stoplamp switch clockwise to detach it from the brake pedal bracket. 4. NOTE: An 11 mm, 12-point socket or wrench can be used to compress the 2 tabs on the brake pedal arm pin. Remove the brake pedal arm pin and disconnect the brake booster push rod from the brake pedal arm. 5. Remove the bulkhead sound insulator. 6. Remove the 4 brake pedal bracket nuts. ^ To install, tighten to 27 Nm (20 ft. lbs.) 7. Remove the 2 brake pedal bracket bolts and remove the brake pedal and bracket. ^ To install, tighten to 27 Nm (20 ft. lbs.) 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Disc Brake System - Exploded View Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6507 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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. Remove the brake caliper flow bolt and the 2 copper washers. ^ Discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Inspect the brake caliper for leaks. ^ If leaks are found, a new brake caliper must be installed. 5. To install, reverse the removal procedure. 6. Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6508 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Disc Brake System - Exploded View - 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6509 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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 2 brake caliper guide pin caps and bolts. ^ Inspect the guide pin threads for damage and inspect the guide pin bushings for damage/wear. Install a new guide pin(s) and bushing(s) as necessary. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Remove the brake caliper and remove the brake pads from the caliper. 5. Inspect the disc brake caliper dust boot for leaks and/or damage. ^ If leaks or damage are found, install a new brake caliper. 6. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6510 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6511 Disc Brake System - Exploded View 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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted or plastic surfaces. Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6512 CAUTION: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. 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 to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. NOTE: The RH side anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 6. Rotate the spring downward and remove it from the brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6513 7. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 8. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 guide pin bushing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ Remove and discard the 2 brake caliper guide pin bushings. 9. Remove the 2 brake caliper anchor plate bolts and the anchor plate. Installation 1. Position the brake caliper anchor plate and install the 2 anchor plate bolts. ^ Tighten to 200 Nm (148 ft. lbs.) 2. Install new brake hardware as follows: 1 Install the guide pin bushings into the caliper bores. 2 Apply grease to the inside of the guide pin bushings. Do not apply grease to the guide pin threads. 3 Push the guide pins into the bushings. 3. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 4. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. ^ Tighten the bolts to 55 Nm (41 ft. lbs.) 5. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated on the anchor plate. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6514 6. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. Install the anchor housing spring using this procedure: 1 Insert the tab of the spring into the brake caliper cavity. 2 Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). 7. NOTE: LH anchor housing spring shown. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 8. NOTE: LH anchor housing spring shown. Position the other anchor housing spring portion onto the anchor plate. 9. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6515 10. NOTE: Latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched by pulling on the spring. 11. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6516 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6517 Disc Brake System - Exploded View - 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. CAUTION: Do not allow the caliper and brake pad assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. ^ Support the caliper using mechanic's wire. ^ Inspect the guide pin threads for damage and inspect the guide pin bushings for wear. Install a new guide pin(s) and bushing(s) as necessary. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ Inspect the caliper anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. ^ To install, tighten to 190 Nm (140 ft. lbs.) 5. To install, reverse the removal procedure. ^ Test the brakes for normal operation. 6. Clean, dry and inspect the brake caliper anchor plate. Apply a light coat of lubricant to the 4 brake pad contact points on the anchor plate as indicated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Pads Minimum thickness............................................................................................................................... ............................................... 2.0 mm (0.079 inch) Maximum thickness variation (pad-to-pad)......................................................................................................................................... 2.0 mm (0.079 inch) Maximum taper wear (in any direction)............................................................................................................................................... 3.0 mm (0.118 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 6522 Brake Pad: Specifications Rear Brake Pads Minimum thickness............................................................................................................................... ............................................... 2.0 mm (0.079 inch) Maximum thickness variation (pad-to-pad)......................................................................................................................................... 2.0 mm (0.079 inch) Maximum taper wear (in any direction)............................................................................................................................................... 3.0 mm (0.118 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6525 Disc Brake System - Exploded View 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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted or plastic surfaces. Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6526 CAUTION: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. 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 to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. NOTE: The RH side anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 6. Rotate the spring downward and remove it from the brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6527 7. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 8. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 guide pin busing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ Remove and discard the 2 brake caliper guide pin bushings. 9. Remove the 2 brake pads from the caliper. 10. Inspect the brake pads for wear and contamination, install new pads as necessary. 11. NOTE: Use a wood block or a used brake pad to protect the brake caliper piston boots. Compress the brake caliper piston. 12. Inspect the brake disc and resurface or install new as necessary. Installation 1. Clean the brake pad contact areas of the brake caliper. 2. Install new brake hardware as follows: 1 Install the guide pin bushings into the caliper bores. 2 Apply grease to the inside of the guide pin bushings. Do not apply grease to the guide pin threads. 3 Push the guide pins into the bushings. 3. Install the inboard brake pad onto the caliper. 4. Rotate the outer brake pad upper and lower retaining springs 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6528 5. Remove the protective paper from the outboard brake pad and install it onto the brake caliper. 6. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 7. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. ^ Tighten the bolts to 55 Nm (41 ft. lbs.) 8. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated on the anchor plate. 9. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. Install the anchor housing spring using this procedure: 1 Insert the tab of the spring into the brake caliper cavity. 2 Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6529 10. NOTE: LH anchor housing spring shown. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. NOTE: LH anchor housing spring shown. Position the other anchor housing spring portion onto the anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. 13. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched by pulling on the spring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6530 14. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6531 Brake Pad: Service and Repair Rear Brake Pads Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6532 Disc Brake System - Exploded View - 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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 suitable suction device, remove brake fluid in the master cylinder reservoir until the 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. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ Inspect the guide pin threads for damage and inspect the guide pin bushings for damage/wear. Install a new guide pin(s) and bushing(s) as necessary. 4. Remove the brake pads from the caliper. 5. 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. 6. Using a suitable clamp, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply a light coat of lubricant to the 4 brake pad contact points on the anchor plate as indicated. 2. Install the brake pads to the caliper. 3. 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.) 4. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc: Specifications Front Brake Disc Minimum thickness............................................................................................................................... .............................................. 27.0 mm (1.06 inch) Minimum thickness to machine............................ ............................................................................................................................... 27.6 mm (1.08 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front > Page 6537 Brake Rotor/Disc: Specifications Rear Brake Disc Minimum thickness............................................................................................................................... ............................................... 19.0 mm (0.74 inch) Maximum runout.................................................. ........................................................................................................................... 0.025 mm (0.001 inch) Maximum thickness variation....................................................................................................... ................................................... 0.013 mm (0.005 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Disc Machining 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-vehicle 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. 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6540 Brake Rotor/Disc: Removal and Replacement Disc Removal and Installation, Front Brake Disc Removal and Installation Disc Brake System - Exploded View 1. Remove the brake caliper anchor plate. 2. Remove the brake disc. 3. To install, reverse the removal procedure. Disc Removal and Installation, Rear Brake Disc Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6541 1. With the vehicle in NEUTRAL. position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the brake caliper and anchor plate assembly to hang by the flexible brake hose or damage to the hose can occur. Remove the brake caliper anchor plate bolts and position the anchor plate and caliper assembly aside. ^ Support the caliper and anchor plate assembly with mechanic's wire. ^ Inspect the anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. ^ To install, tighten to 190 Nm (140 ft. lbs.) 3. NOTE: If the brake disc binds on the parking brake shoe, remove the adjustment hole access plug and contract the parking brake shoe. Remove the brake disc. 4. Inspect the brake disc and resurface or install a new brake disc as necessary. 5. To install, reverse the removal procedure. Shield Removal and Installation, Front Brake Disc Shield Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6542 Disc Brake System - Exploded View 1. Remove the brake disc. 2. Remove the brake disc shield screws. ^ To install, tighten to 17 Nm (13 ft. lbs.) 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6548 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6549 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6550 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6551 Brake Bleeding: Service and Repair Gravity Gravity 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. ^ Open the bleeder screw and leave open until clear bubble-free brake fluid flows. Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6552 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6553 Brake Bleeding: Service and Repair Manual Manual 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6554 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6555 Brake Bleeding: Service and Repair Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6556 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS) 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6557 with pressure bleeding equipment. NOTE: This procedure must be performed if the anti-lock brake (ABS) 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 ABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleeding removes the air from the system. NOTE: Add clean, specified brake fluid as necessary throughout the procedure. 1. Connect a clear hose to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with clean, specified 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 scan tool. Connect the scan tool to the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Gravity Gravity Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6558 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 clean, specified 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6559 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified 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 hose to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6560 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 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6561 NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough clean, 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 clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the 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 hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified 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. 8. Fill the brake master cylinder reservoir with clean, specified brake fluid and install the brake master cylinder filler cap. Master Cylinder, Bench Master Cylinder, Bench Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6562 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder, In Vehicle > Page 6563 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 (2007)) 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 Disc Brake System - Exploded View Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6568 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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. Remove the brake caliper flow bolt and the 2 copper washers. ^ Discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Inspect the brake caliper for leaks. ^ If leaks are found, a new brake caliper must be installed. 5. To install, reverse the removal procedure. 6. Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6569 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Disc Brake System - Exploded View - 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6570 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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 2 brake caliper guide pin caps and bolts. ^ Inspect the guide pin threads for damage and inspect the guide pin bushings for damage/wear. Install a new guide pin(s) and bushing(s) as necessary. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Remove the brake caliper and remove the brake pads from the caliper. 5. Inspect the disc brake caliper dust boot for leaks and/or damage. ^ If leaks or damage are found, install a new brake caliper. 6. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6571 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6572 Disc Brake System - Exploded View 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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted or plastic surfaces. Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6573 CAUTION: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring can occur. 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 to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. NOTE: The RH side anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. For the RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force to the center of the spring and pull outward at the top of the spring to remove it from the upper brake caliper cavity. 6. Rotate the spring downward and remove it from the brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6574 7. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 8. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 guide pin bushing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ Remove and discard the 2 brake caliper guide pin bushings. 9. Remove the 2 brake caliper anchor plate bolts and the anchor plate. Installation 1. Position the brake caliper anchor plate and install the 2 anchor plate bolts. ^ Tighten to 200 Nm (148 ft. lbs.) 2. Install new brake hardware as follows: 1 Install the guide pin bushings into the caliper bores. 2 Apply grease to the inside of the guide pin bushings. Do not apply grease to the guide pin threads. 3 Push the guide pins into the bushings. 3. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 4. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. ^ Tighten the bolts to 55 Nm (41 ft. lbs.) 5. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated on the anchor plate. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6575 6. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. Install the anchor housing spring using this procedure: 1 Insert the tab of the spring into the brake caliper cavity. 2 Twist the tab into the cavity (LH side in the upper brake caliper cavity, RH side in the lower brake caliper cavity). 7. NOTE: LH anchor housing spring shown. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 8. NOTE: LH anchor housing spring shown. Position the other anchor housing spring portion onto the anchor plate. 9. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6576 10. NOTE: Latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched by pulling on the spring. 11. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6577 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6578 Disc Brake System - Exploded View - 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. CAUTION: Do not allow the caliper and brake pad assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. ^ Support the caliper using mechanic's wire. ^ Inspect the guide pin threads for damage and inspect the guide pin bushings for wear. Install a new guide pin(s) and bushing(s) as necessary. ^ To install, tighten to 35 Nm (26 ft. lbs.) 4. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ Inspect the caliper anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. ^ To install, tighten to 190 Nm (140 ft. lbs.) 5. To install, reverse the removal procedure. ^ Test the brakes for normal operation. 6. Clean, dry and inspect the brake caliper anchor plate. Apply a light coat of lubricant to the 4 brake pad contact points on the anchor plate as indicated. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. .................................................................. PM-1-C Ford Specification ............................................... ..................................................................................................................................... WSS-M6C62-A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6585 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6589 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. 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 the master cylinder brake tube fittings to 25 Nm (18 ft. lbs.) - tighten the remaining brake tube fittings to 20 Nm (15 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Master Cylinder, In Vehicle Master Cylinder, In Vehicle 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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. 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 clean, specified brake fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6594 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 fitting 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 tube fittings. ^ Tighten to 25 Nm (18 ft. lbs.) Master Cylinder, Bench Master Cylinder, Bench 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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 clean, 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6595 with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with clean, specified 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6596 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 6597 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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. 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. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the brake fluid level switch. 3. Loosen the brake tube fittings and disconnect the brake tubes. ^ Plug the master cylinder ports. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. Remove the 2 brake master cylinder nuts and the brake master cylinder. ^ To install, tighten to 25 Nm (18 ft. lbs.) 5. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Parking Brake Release Solenoid Parking Brake Release Solenoid Removal and Installation 1. Disconnect the parking brake release solenoid electrical connector. 2. Remove the parking brake release solenoid. ^ Pry the mounting bracket apart slightly to release the solenoid. ^ Disengage the solenoid from the release lever. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Tension Release 1. Remove the LH cowl side trim panel. For additional information, refer to Trim Panel. 2. With the help of an assistant, release the parking brake cable tension by pulling down on the intermediate cable at the cable-to-cable connector clip until the parking brake control sector rotates to its stop and a 4 mm (0.15 inch) x 150 mm (5.9 inch) retainer pin can be inserted. 3. Disconnect the cable-to-cable connector clip. 4. To reload the tension on the parking brake cable, follow the release procedure in reverse. ^ Make sure the cable-to-cable connector clip is connected to the front and rear cable before removing the brake control retaining pin, and the cable tension is reloaded slowly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6606 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Removal and Installation 1. Relieve the tension on the parking brake cable system. 2. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6607 1 Compress the 2 tabs. 2 Remove the conduit from the bracket. 5. NOTE: Be sure to correctly install the park brake cable retainer spring and route cables between suspension links. Remove the LH rear cable. 1 Remove the LH rear cable from the retaining clip. 2 Disconnect the park brake cable retainer spring. 3 If equipped, disconnect the anti-lock brake system (ABS) sensor wire from the retaining clip. 6. Remove the wireform bracket retaining bolt and the bracket. ^ To install, tighten to 17 Nm (13 ft. lbs.) 7. Compress the retainer and release the conduit, then unclip the cable end fitting from the parking brake shoe lever. 8. To install, reverse the removal procedure. Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6608 Parking Brake Cable - Rear, RH Removal and Installation 1. Relieve the tension on the parking brake cable system. 2. 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 from the cable union. 4. Compress the 2 tabs and release the conduit from the equalizer. 5. Remove the RH rear cable from the retaining clip. 6. Remove the bolt and the wire form bracket from the LH side of the vehicle. ^ To install, tighten to 18 Nm (13 ft. lbs.) 7. Remove the rear park brake cable-to-crossmember bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6609 ^ To install, tighten to 9 Nm (80 inch lbs.) 8. Remove the bolt and the wire form bracket from the RH side of the vehicle. ^ To install, tighten to 18 Nm (13 ft. lbs.) 9. Compress the 2 tabs and release the conduit, then unclip the cable end fitting from the parking brake shoe lever. 10. To install, reverse the removal procedure. Parking Brake Cable - Front Parking Brake Cable - Front Parking Brake Cable - Front Removal and Installation 1. Remove the parking brake control. 2. 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6610 3. Remove the front park brake cable P-clip-to-frame bolt. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. 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. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Parking Brake Control Removal and Installation 1. Relieve tension on the parking brake cable system. 2. If equipped, remove the parking brake release solenoid. 3. Remove the door scuff plate. 4. Remove the 2 screws and the instrument panel steering column cover. ^ Pull the weatherstrip back to release the edge of the panel. 5. Remove the parking brake release handle bolt. ^ To install, tighten to 3 Nm (27 inch lbs.) 6. Remove the retainer and the cowl trim panel. 7. Compress the 2 tabs and disconnect the parking brake release cable from the parking brake control assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 6614 8. Disconnect the parking brake release cable from the release lever and remove the parking brake release handle. 9. Disconnect the parking brake switch electrical connector. 10. Remove the 3 parking brake control assembly bolts. ^ To install, tighten to 20 Nm (15 ft. lbs.) 11. Position the parking brake control assembly onto the floor. 12. Disconnect the parking brake cable from the take-up spool. 13. Compress the 2 tabs, disconnect the parking brake cable from the control assembly and remove the control assembly. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Diagrams C2132 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6621 Removal 1. Relieve the tension on the parking brake cable system. 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. CAUTION: Apply the grease only where indicated, do not apply the grease to the parking brake shoes. The grease will contaminate the brake shoe linings and damage to the linings will result. Apply a light coat of grease to the 6 parking brake shoe contact points on the disc brake shield. 2. Install the rear parking brake shoe. ^ Hold the rear parking brake shoe in position. ^ Install the retaining pin and clip. 3. Install the front parking brake shoe. ^ Install the parking brake shoe return spring to the rear parking brake shoe and to the front parking brake shoe. ^ Rotate the front parking brake shoe into the guide flange. 4. Slide the front parking brake shoe down into position on the flange. 5. Install the front parking brake shoe retaining pin and clip. 6. Install the parking brake shoe adjuster spring. 7. Install the parking brake shoe adjuster. ^ Using a suitable tool, spread the bottom of the parking brake shoes apart. ^ Install the parking brake shoe adjuster. 8. Using the special tool, measure the inside diameter of the drum portion of the rear brake disc. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6622 ^ Record the measurement. 9. 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 0.45 mm (0.02 inch) less than the recorded inside diameter of the drum portion of the rear brake disc. 10. Install the brake disc. 11. 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. 12. Check the parking brake for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 6626 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6631 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Torque Specifications Torque Specifications (Part 1) Torque Specifications (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Brake Booster Vacuum Brake Booster: Description and Operation Brake Booster 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Brake Booster > Page 6637 Vacuum Brake Booster: Description and Operation Hose and Check Valve 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 6638 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 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. 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. Brake Master Cylinder - Bypass Condition 1. Disconnect the brake tubes 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 a new one must be installed. Brake Master Cylinder - Compensator Port 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 tubes 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 6639 Vacuum Brake Booster: Service and Repair Brake Booster Brake Booster Removal and Installation All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the clamp and separate the air cleaner outlet tube and resonator from the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 6640 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 fluid reservoir screws and position the reservoir aside. ^ To install, tighten to 11 Nm (8 ft. lbs.) 6. Depress the brake pedal at least 3 times to deplete the vacuum in the booster. 7. Disconnect the brake fluid level switch. 8. NOTE: Support the master cylinder with mechanic's wire. Remove and discard the 2 brake master cylinder nuts and position the master cylinder aside. ^ To install, tighten to 25 Nm (18 ft. lbs.) 9. Remove the 2 degas bottle bolts and position the degas bottle aside. ^ To install, tighten to 9 Nm (80 inch lbs.) Vehicles equipped with roll stability control 10. Disconnect the brake pedal travel solenoid electrical connector. All vehicles 11. Disconnect the brake pedal travel sensor electrical connector. 12. Disconnect the manifold vacuum outlet assembly from the brake booster. 13. CAUTION: Always remove the stoplamp switch with the brake pedal secured to the brake booster push rod and with the brake pedal in the at-rest position. Do not press or pull on the brake pedal when removing the switch or damage to switch can occur. CAUTION: The stoplamp switch must be removed prior to removing the brake pedal and bracket, brake booster and associated mounting fasteners or damage to the switch can occur. Disconnect the electrical connector and turn the stoplamp switch clockwise to detach it from the brake pedal bracket. 14. Remove the brake pedal arm pin and disconnect the booster push rod from the brake pedal arm. 15. Remove the 4 brake booster-to-pedal bracket nuts and remove the brake booster. ^ To access the retaining nuts, fold back the sound insulation. ^ To install, tighten to 27 Nm (20 ft. lbs.) 16. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 6648 C2142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6658 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6659 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6665 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6666 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6667 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6668 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6669 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module 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 air cleaner outlet pipe from the air cleaner cover. ^ to install, tighten the clamps to 4 Nm (35 inch lbs.) 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Release the retaining clips and position the air cleaner cover aside. 5. Remove the 3 hydraulic control unit (HCU) bracket bolts. ^ To install, tighten to 20 Nm (15 ft. lbs.) 6. Disconnect the anti-lock brake system (ABS) module electrical connector. 7. Remove the 4 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.) 8. To install, reverse the removal procedure. ^ If installing a new ABS module, program the module. For additional information, refer to Information Bus (Module Configuration). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 6673 C2142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6678 View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6679 C3073 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6680 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6681 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6685 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6689 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 6693 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 6697 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: Customer Interest ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 6706 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6711 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6712 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set TSB 08-20-8 10/13/08 STEERING WHEEL ANGLE CIRCUIT AND/OR SIGNAL FAILURE - C1277-C1278 - BUILT ON/OR BEFORE 4/10/2008 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 08-10-3 to update the Part List and Service procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built on or before 4/10/2008 may exhibit a traction control light (TCL) on with diagnostic trouble codes (DTCs) C1277 and/or C1278 (steering wheel angle 1 and 2 circuit failure and/or signal faulted). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check to see if the steering wheel rotation (SWR) sensor wiring near the connector has come in contact with or is touching the brake pedal bracket. Vibration of the harness may cause interruption in the SWR signal. a. If yes, go to Step 2. b. If no, do not continue with this procedure. Refer to normal diagnosis in the Workshop Manual (WSM), Section 206-09. 2. Repair any chafing that may have occurred. 3. Move the harness towards the driver's side of the vehicle and tuck in front of the 14401 harness above the steering column. Use a tie strap to secure in place. 4. Replace the SWR sensor following WSM, Section 206-09. 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 082008A 2007-2008 Expedition, 0.7 Hr. Navigator: Replace The Steering Wheel Rotation Sensor, Includes Time To Reposition Harness, Check DTCs, Repair Wires If Required, And Calibrate New Sensor. (Do Not Use With 12650D, 14200A) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-20-8 > Oct > 08 > ABS/TCS - TC Lamp ON/DTC C1277/C1278 Set > Page 6718 BASIC PART NO. CODE 14401 12 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6723 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6724 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 6725 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 3 Nm (27 inch lbs.) 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6729 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6730 Traction Control Switch: Service and Repair Stability/Traction Control Switch - Expedition Stability/Traction Control Switch - Expedition Removal and Installation 1. Remove the lower instrument cluster center finish panel. 2. Remove the upper instrument cluster center finish panel. ^ Disconnect the electrical connectors. 3. Depress the 4 tabs and remove the traction control switch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6731 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6740 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6741 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 6746 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Wheel Speed Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6752 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6753 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/Normal Brake Operation TSB 07-25-6 12/24/07 ABS LIGHT ON - VEHICLES BUILT BEFORE 2/15/2007 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 02/15/2007 may experience an ABS light on and the base brake system continuing to function normally. This may be due to corrosion in the connector of the rear wheel speed sensor. ACTION Follow the Service Procedure steps to correct the condition as it may be necessary to replace the rear wheel speed sensor and the female side of the connector. SERVICE PROCEDURE Follow normal Workshop Manual (WSM) diagnostics. If the diagnostics lead to replacement of the rear wheel speed sensor, follow these steps to prevent water leaking into the connector. 1. Disconnect the rear wheel speed sensor connector. 2. Inspect the female terminals, on the harness side of the connector (C440 and C426). 3. If corrosion or evidence of water damage is present, replace the connector with wiring pigtail kit and follow the instruction sheet which is included. 4. Replace rear wheel speed sensor. Refer to WSM, Section 206-09. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072506A 2007 Expedition/Navigator: 1.8 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: One Side (Do Not Use With 2219D, 2219D5, 14200A) 072506B 2007 Expedition/Navigator: 2.4 Hrs. Replace Wheel Speed Sensor And, Harness Side Female Wiring Connector, Includes Time To Diagnose: Both Sides (Do Not Use With 2219D, 2219D5, 14200A) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 07-25-6 > Dec > 07 > Brakes - ABS Lamp ON/Normal Brake Operation > Page 6758 DEALER CODING CONDITION BASIC PART NO. CODE 2C204 95 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 6761 Wheel Speed Sensor: Locations Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left/Right Front > Page 6762 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6765 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6766 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6767 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) 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 6770 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear 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 (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: Customer Interest ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6779 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Customer Interest for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6780 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set Yaw Rate Sensor: All Technical Service Bulletins ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set TSB 08-14-2 07/21/08 STABILITY/TRACTION CONTROL INDICATOR - SLIDING-CAR ICON-ON OR FLASHING - DTC C1996 OR SENSITIVE ESC/RSC ACTIVATION NO CODES FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with electronic stability control (ESC)/roll stability control (RSC) may exhibit the stability/traction control indicator "sliding-car icon" on or flashing with diagnostic trouble code (DTC) C1996 or sensitive ESC/RSC activation with no codes. ACTION Follow the Service Procedure steps to correct the condition. SERVICE EVALUATION PROCEDURE Determine if this procedure applies by answering the following questions: 1. Was the customer pulling a trailer when the concern occurred? a. No, go to question 2. b. Yes, do not proceed with this procedure. Vehicles pulling heavy trailers have the possibility to have a sensitive activation or DTC C1996. This is a normal characteristic and no corrective action needed. 2. Was the stability/traction control indicator "sliding-car icon" on or flashing during the concern? a. No, do not proceed with this procedure and refer to normal workshop manual diagnostics. b. Yes, proceed to question 3. 3. Did the concern occur during acceleration? a. Yes, proceed to question 4. b. If no, go to question 5. 4. Test drive the vehicle on curves and/or bumpy roads. Monitor all four wheel speed sensors. ^ Left Front Wheel Speed Sensor (LF_WSPD). ^ Right Front Wheel Speed Sensor (RL_WSPD). ^ Left Rear Wheel Speed Sensor (LR_WSPD). ^ Right Rear Wheel Speed Sensor (RR_WSPD). ^ Are the values similar +/- 6 MPH (10 Km/h)? a. No, they vary, proceed to Diagnostic Service Procedure Step 5. b. Yes, go to question 5. 5. Has this concern occurred more than once? Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6786 a. Yes, go to question 6. b. No, go to Diagnostic Service Procedure Step 1. 6. Has the Stability Control Sensor Cluster been previously replaced? a. Yes, go to Diagnostic Service Procedure Step 6. b. No, go to question 7. 7. Did the activation occur in less than 2 minutes after starting and driving the vehicle? a. Yes, go to Diagnostic Service Procedure Step 6. b. If no, go to Diagnostic Service Procedure Step 1. DIAGNOSTIC SERVICE PROCEDURE 1. Are after market accessories installed? a. Yes, repair sources of vibration (sub-woofer, modified center console). Proceed to Step 2. b. No, proceed to Step 2. 2. Steering wheel angle (SWA) sensor inspection. a. Visually inspect the optical tone ring for contamination or debris. (1) Clean as necessary. b. Inspect the SWA connector for looseness. Reconnect as necessary. (1) Push, click, and pull to verify a good connection. c. Visually inspect around the area of the steering column/tone ring for signs of light entering the cabin, shining through the windshield between the defroster grill and instrument panel (IP). Defroster grill variation may allow for slight gaps, enough to leak light. (1) Use IP colored foam to block any gaps (tape not recommended as it may loosen and fall off). (2) If no problems found with the SWA system, proceed to Step 3. 3. Inspect mounting/torque of the bolts holding the stability control sensor cluster in position. a. Look for looseness of bolts or distortion of the sheet metal. b. Check the connector (pin push outs) and wiring (chafe) to the stability control sensor cluster. c. If no problems found with the stability control sensor cluster proceed to Step 4. 4. Start engine and keep vehicle at a stand still. Monitor the YAW rate PID value for the Stability Control Sensor Cluster. Expected values: +/- 2.0 d/s YAW. a. If not within specification, replace the Stability Control Sensor Cluster per the Workshop Manual (WSM), Section 206-09: Vehicle Dynamic Systems. b. If within specification, go to Step 5. 5. Refer to Symptom Chart in the WSM, Section 206-09: Vehicle Dynamic Systems: Unintended ABS activation, ABS too sensitive, ABS activates on a normal stop. a. If no problem found with the base brakes or wheel speed sensors, proceed to Step 6. 6. If all steps above have no concern or are repaired and concern still exhibited, or you have been previously directed to this step, replace the ABS module per the WSM, Section 206-09: Vehicle Dynamic Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Yaw Rate Sensor: > 08-14-2 > Jul > 08 > ABS/TCS - Sliding Car Icon ON/Flashing/DTC C1996 Set > Page 6787 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 MT081402 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 2C219 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 6788 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster 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 4 bolts and the bracket. ^ To install: Tighten the upper bolts to 9 Nm (80 inch lbs.) - Tighten the lower bolts to 40 Nm (30 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Technical Service Bulletins > Page 6789 4. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.) 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6797 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 6803 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6806 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6807 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6808 Starter Relay: Testing and Inspection Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6809 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6810 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 6815 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 battery ground cable terminal aside at the starter. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the nut and position the starter solenoid positive cable terminal aside. - To install, tighten to 12 Nm (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. Remove the 2 nuts and position the 2 battery cable harness brackets from the A/C compressor mounting bolts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the bolt and position the battery ground cable-to-frame terminal aside. - To install, tighten to 15 Nm (11 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, release the harness locator and remove the battery cable harness assembly. 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Voltage................................................................................................................................................. ........................................................................12 volts Generator amps...............................................................................89/157 amp (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Generator Load at 2,000 rpm................................................................................................................................ ....................................................................89 amps No Load at 2,000 rpm........................................ .......................................................................................................................between 13.2 and 15.5 volts Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 6821 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 orientation. 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 (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Alternator: Connector Views C102A C102B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6842 Alternator: Application and ID Item....................................................................................................................................................... ..............................................................Specification Generator Rating..............................................................................................89/157 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 (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6843 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. The generator and voltage regulator are repaired as an assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6844 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6845 5. Remove the harness locator from the generator bracket. 6. Remove the 4 bolts and the generator bracket. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the 2 bolts and position the generator aside. - Tighten to 25 Nm (18 lb-ft). 8. Disconnect the generator electrical connector. 9. Position the generator B+ protective cover aside, remove and discard the nut, then position the generator B+ terminal aside. - Install a new B+ terminal nut; 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 (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6852 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Starting System 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 (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 6857 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6858 View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6859 Starter Motor: Diagrams C197A C197B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor - Load Test Starter Motor: Testing and Inspection Starter Motor - Load Test STARTER MOTOR - LOAD TEST WARNING: When servicing the starter motor or carrying out other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times. Failure to follow these instructions may result in personal injury. CAUTION: A protective cap or boot is provided over the battery input terminal on all car lines and must be installed after repair. Be sure to disconnect the battery ground cable before repairing the starter motor. 1. Before carrying out this test inspection, check the battery to determine its state of charge. Carry out a load test of the battery using the Starter, Alternator, Battery, Regulator and Electrical (SABRE) Tester. Refer to Charging System for the test procedure. 2. Disconnect the ignition coil connector from the ignition coil. 3. Connect the SABRE tester to the vehicle using the amperage lead clipped around the positive battery cable. 4. Measure the amperage of the starter motor while activating the starting system. 5. A correctly operating starter motor will draw from 130 to 190 amps of current at room temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor - Load Test > Page 6862 Starter Motor: Testing and Inspection Starter Drive Test STARTER DRIVE TEST 1. Remove the starter motor. 2. Secure the starter motor in a vise. 3. Connect the battery ground cable of a fully charged battery to the case of the starter motor. 4. CAUTION: Do not leave the positive lead of the battery connected to the starter motor S-terminal for more than 10 seconds. Touch the positive lead from the battery to the S-terminal and verify that the starter drive ejects. 5. Remove the positive lead from the starter motor. The ejected starter drive should return to its original position. 6. If the starter drive does not eject and return to position, install a new starter motor. 7. Check the starter drive. It should turn freely in one direction, and positively engage to the armature when turned in the opposite direction. If not as specified, install a new starter motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor - Load Test > Page 6863 Starter Motor: Testing and Inspection Starter Motor - No load test STARTER MOTOR - NO-LOAD TEST The starter No Load Test will identify open or shorted windings and a possible rubbing starter motor armature or bent starter motor armature shaft. 1. WARNING: Make sure that the starter motor is securely mounted on a bench because the starter motor may move or jump when it is energized. Failure to follow these instructions may result in personal injury. Connect a fully charged battery, a Starter, Alternator, Battery, Regulator and Electrical (SABRE) Tester and a remote starter switch to the starter motor. Connect the remote starter switch between the battery positive (+) post and the starter motor S-terminal. Connect the starter motor B-terminal to the battery positive (+) post. Connect the SABRE positive (+) terminal and negative (-) terminal to the corresponding battery post. Make sure that the battery and starter motor are grounded. 2. Engage the remote starter switch. 3. The starter motor should eject the starter drive and run smoothly. If the starter motor does not run smoothly, install a new starter motor. 4. While the starter motor is running, check the voltmeter and ammeter. 5. The amperage should be no more than 84 amps. 6. If the amperage is higher than 84 amps, install a new starter motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 6864 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 6865 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 1. Position the starter and install the 2 bolts and the stud bolt in 3 stages. - Stage 1: Install the 2 starter bolts and the stud bolt finger tight. - Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft). - Stage 3: Tighten the lower bolt and stud bolt to 25 Nm (18 lb-ft). 2. Position the starter battery ground cable onto the stud and install the nut. - Tighten to 25 Nm (18 lb-ft). 3. Connect the solenoid B-terminal electrical connection and install the nut. - Tighten to 12 Nm (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 (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay > Page 6870 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6873 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6874 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6875 Starter Relay: Testing and Inspection Starter Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6876 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6877 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6883 C2033 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6884 C3063 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6885 C3064 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6890 C194 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6895 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6896 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6897 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6898 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6899 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6900 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6901 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6902 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6903 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 6904 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 orientation. 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6926 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6927 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6928 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6929 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6930 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6931 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6932 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6933 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6934 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6935 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6940 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6941 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6942 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6943 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6944 Fuse Block: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6945 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6946 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6947 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6948 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 6949 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 orientation. 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Fuse Block: Connector Views C1035 C2280A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 C2280B C2280C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6977 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6978 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6979 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6980 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6981 Fuse Block: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6982 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6983 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6984 Fuse Block: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6985 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 6986 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6990 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6991 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6995 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6996 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 Multiple Junction Connector: Diagrams C133-C327 C133 C134 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7001 C139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7002 C140 C144 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7003 C145 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7004 C146 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7005 C192 C210 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7006 C211 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7007 C212 C213 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7008 C214 C219 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7009 C237 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7010 C238 (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7011 C238 (Part 2) C248 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7012 C291 C298 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7013 C299 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7014 C311 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7015 C312 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7016 C313 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7017 C314 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7018 C315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7019 C316 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7020 C327 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7021 Multiple Junction Connector: Diagrams C328-C3052 C328 C405 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7022 C406 C408 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7023 C410 C411 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7024 C342 C431 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7025 C432 C465 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7026 C494 C495 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7027 C510 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7028 C610 C700 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7029 C800 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7030 C913 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7031 C922 C934 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7032 C935 C991 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7033 C1026 C2239 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7034 C3049 C3050 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7035 C3051 C3052 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair SMART JUNCTION BOX (SJB) Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new SJB after installation. 1. NOTE: - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - A new SJB is delivered in "manufacturing mode" with 7 pre-set DTCs. These 7 manufacturing mode DTCs require that a successful configuration of the SJB occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. All of this is required in order to clear the 7 manufacturing mode DTCs. The 7 manufacturing mode DTCs are as follows: B2477 (Module Configuration Failure) - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-state) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the pin-type retainer and the RH A-pillar lower trim panel. 4. Remove the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 7039 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. - Tighten the screws to 2 Nm (18 lb-in). 2. Connect the 7 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 the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicate the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. Carry out the SJB on-demand self-test by clearing DTCs and then retrieving DTCs to confirm all DTCs have been cleared. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7044 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7045 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7048 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7049 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7050 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7051 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7052 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7053 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7054 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7055 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 7060 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7061 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 7065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7066 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair SMART JUNCTION BOX (SJB) Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new SJB after installation. 1. NOTE: - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - A new SJB is delivered in "manufacturing mode" with 7 pre-set DTCs. These 7 manufacturing mode DTCs require that a successful configuration of the SJB occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. All of this is required in order to clear the 7 manufacturing mode DTCs. The 7 manufacturing mode DTCs are as follows: B2477 (Module Configuration Failure) - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-state) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the pin-type retainer and the RH A-pillar lower trim panel. 4. Remove the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 7070 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. - Tighten the screws to 2 Nm (18 lb-in). 2. Connect the 7 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 the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicate the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. Carry out the SJB on-demand self-test by clearing DTCs and then retrieving DTCs to confirm all DTCs have been cleared. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7075 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7076 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7079 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7080 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7081 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7082 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7083 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7084 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7085 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7086 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7091 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7092 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7093 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7094 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7095 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7096 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7097 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7098 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7099 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7100 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7103 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7104 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7105 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7106 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7107 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7110 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7111 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7112 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7113 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7114 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7116 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7117 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7118 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7119 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7124 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7125 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7126 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7127 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7128 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7129 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7130 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7131 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7132 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7133 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7136 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7137 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7138 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7139 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7140 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7143 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7144 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7145 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7146 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7147 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7148 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7150 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7151 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7152 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7157 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 (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7158 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7164 C2033 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7165 C3063 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7166 C3064 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 7171 C194 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7176 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7177 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7178 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7180 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7181 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7182 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7183 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7184 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 1 > Page 7185 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 orientation. 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7207 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7208 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7209 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7210 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7211 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7212 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7213 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7214 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7215 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7216 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7221 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7222 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7223 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7224 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7225 Fuse Block: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7227 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7228 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7229 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Auxiliary Relay Box 1 > Page 7230 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 orientation. 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Fuse Block: Connector Views C1035 C2280A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 C2280B C2280C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7258 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7259 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7260 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7261 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7262 Fuse Block: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7263 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7264 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7265 Fuse Block: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7266 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Auxiliary Relay Box 1 > Page 7267 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7271 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7272 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7276 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7277 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 Multiple Junction Connector: Diagrams C133-C327 C133 C134 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7282 C139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7283 C140 C144 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7284 C145 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7285 C146 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7286 C192 C210 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7287 C211 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7288 C212 C213 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7289 C214 C219 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7290 C237 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7291 C238 (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7292 C238 (Part 2) C248 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7293 C291 C298 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7294 C299 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7295 C311 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7296 C312 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7297 C313 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7298 C314 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7299 C315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7300 C316 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7301 C327 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7302 Multiple Junction Connector: Diagrams C328-C3052 C328 C405 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7303 C406 C408 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7304 C410 C411 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7305 C342 C431 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7306 C432 C465 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7307 C494 C495 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7308 C510 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7309 C610 C700 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7310 C800 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7311 C913 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7312 C922 C934 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7313 C935 C991 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7314 C1026 C2239 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7315 C3049 C3050 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C133-C327 > Page 7316 C3051 C3052 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair SMART JUNCTION BOX (SJB) Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new SJB after installation. 1. NOTE: - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - A new SJB is delivered in "manufacturing mode" with 7 pre-set DTCs. These 7 manufacturing mode DTCs require that a successful configuration of the SJB occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. All of this is required in order to clear the 7 manufacturing mode DTCs. The 7 manufacturing mode DTCs are as follows: B2477 (Module Configuration Failure) - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-state) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the pin-type retainer and the RH A-pillar lower trim panel. 4. Remove the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 7320 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. - Tighten the screws to 2 Nm (18 lb-in). 2. Connect the 7 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 the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicate the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. Carry out the SJB on-demand self-test by clearing DTCs and then retrieving DTCs to confirm all DTCs have been cleared. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7325 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7326 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7329 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7330 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7331 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7332 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7333 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7334 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7335 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7336 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7341 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7342 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7346 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7347 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair SMART JUNCTION BOX (SJB) Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new SJB after installation. 1. NOTE: - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - A new SJB is delivered in "manufacturing mode" with 7 pre-set DTCs. These 7 manufacturing mode DTCs require that a successful configuration of the SJB occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. All of this is required in order to clear the 7 manufacturing mode DTCs. The 7 manufacturing mode DTCs are as follows: B2477 (Module Configuration Failure) - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-state) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the pin-type retainer and the RH A-pillar lower trim panel. 4. Remove the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 7351 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. - Tighten the screws to 2 Nm (18 lb-in). 2. Connect the 7 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 the SJB operation and clears DTCs B2477 and B106D. The clearing of these DTCs indicate the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. NOTE: DTC C2780 will not clear if any other DTCs are present in the SJB. Carry out the SJB on-demand self-test by clearing DTCs and then retrieving DTCs to confirm all DTCs have been cleared. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7356 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 7357 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7362 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7363 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7364 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7365 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7366 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Left/Right Turn > Page 7367 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7372 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7373 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7374 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7375 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7376 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7377 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7378 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7379 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7380 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7381 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7384 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7385 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7386 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7387 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7388 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7391 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7392 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7393 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7394 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7395 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7396 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7397 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7398 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7399 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7400 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7405 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7406 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7407 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7408 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7409 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7410 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7411 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7412 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7413 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 1 > Page 7414 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) C1035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7417 Relay Box: Diagrams Smart Junction Box (SJB) C2280A C2280B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7418 C2280C C2280D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7419 C2280E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7420 C2280F Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7421 C2280G Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7424 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7425 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7426 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7427 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7428 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7429 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7430 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7431 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7432 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel > Page 7433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7438 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 (2007)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7439 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7445 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7446 Alignment: Specifications Ride Height Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7447 Part 2 Of 3 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7448 Alignment: Specifications Alignment Specifications Vehicles With Rear Coil Spring Suspension Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7449 Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7450 Alignment: Specifications Alignment Specifications Vehicles With Rear Air Suspension Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7451 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7452 Alignment: Specifications Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7453 Part 2 Of 2 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7454 Part 2 Of 3 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7455 Alignment Specifications Vehicles With Rear Coil Spring Suspension Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7456 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7457 Alignment Specifications Vehicles With Rear Air Suspension General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7458 General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 7459 General Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7460 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 removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct affect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting does not affect tire wear. Toe Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7461 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7462 Front Ride Height Measurement Rear Ride Height Measurement 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 (2007)) 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 kit (3B236 for the front and 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. NOTE: The lower arm front and rear bolts must be tightened with the weight of the vehicle resting on the wheel and tire assembles. While holding the cam bolt, tighten the nut to 350 Nm (258 lb-ft). 6. Check and, if necessary, adjust the front toe. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 7465 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod. Rotate the tie rod(s) to achieve the desired toe setting.! 7. 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 115 Nm (85 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 7466 8. Install the steering gear bellows clamp(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 7467 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. NOTE: Before carrying out a toe adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link cam bolt nut(s). 3. Rotate the toe link cam bolt(s) until the toe setting is within specification. 4. NOTE: Make sure the toe settings are not disturbed while tightening the cam nut(s). Tighten the toe link cam bolt nut(s) to 275 Nm (203 lb-ft). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 7468 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear camber. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear camber value is not within specification, go to the next step. 2. Remove the upper arm-to-frame bolt and the camber set shim. ^ Discard the camber set shim. ^ Install and snug the upper arm-to frame bolt. 3. Position the upper arm-to-frame bolt in the upper arm-to-frame slot until the camber setting is within specification. 4. NOTE: Do not allow the upper arm to move and change the camber adjustment setting when tightening the bolt. Tighten the upper arm-to-frame bolt to 300 Nm (221 lb-ft). 5. Recheck the camber setting, adjust as necessary. 6. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment-Front > Page 7469 Alignment: Service and Repair Ride Height Adjustments (Vehicle Dynamic Suspension) Ride Height Adjustments Special Tool(s) CAUTION: The suspension height D dimensions are for reference only. The vehicle attitude must be controlled by the correct dimensions to prevent vehicle damage. NOTE: If one or both height sensors are installed new, both height sensors must be calibrated. NOTE: Incorrect air suspension ride height D dimension can be caused by an air suspension system that is incorrectly set. NOTE: The air suspension module has a preprogrammed trim height. 1. NOTE: The vehicle must be on a level surface, such as a drive on alignment hoist. Position the vehicle on a level surface. 2. Using the vehicle message center, verify that the air suspension is in the ON mode. 3. Using the scan tool, run the accurate trim test. 4. Measure the ride height D dimension. 5. If ride height dimension D is not within specification, use the scan tool to vent or fill the air suspension to the correct dimension. 6. NOTE: The air suspension height sensor sends a signal to the air suspension module. The output ranges from approximately 4.5 volts at minimum height (when the vehicle is low or in full jounce) to 0.5 volt at maximum height (when the vehicle is in high or in full rebound). Using the scan tool, monitor the 2 suspension height sensors voltage parameter identifications (PIDs). 7. Using the scan tool, save the vehicle's trim height for both sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7475 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7476 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7477 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 7481 Suspension Control Module: Diagrams C2131A C2131B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 7482 Suspension Control Module: Service and Repair Air Suspension 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. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 lb-in). 4. 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 LH and RH ride height sensors are calibrated and a pneumatic test is carried out. For additional information, refer to Vehicle Dynamic Suspension Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 7489 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7493 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 7504 RH Side Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the senor harness from the sensor bracket. 3. Disconnect the sensor electrical connector. 4. Disconnect the sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 sensor bolts. ^ To install, tighten to 11 Nm (8 lb-ft). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7508 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 7513 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7516 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7517 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7518 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7519 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7520 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7521 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7526 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 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. CAUTION: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. CAUTION: When servicing the lower shock nut, take care not to damage the stabilizer link. 1. Remove the wheel bearing and wheel hub. 2. Remove and discard the tie-rod end nut. ^ To install, tighten to 115 Nm (85 lb-ft). 3. Using the special tool, separate the tie-rod end from the wheel knuckle. 4. Remove the wheel speed sensor harness bracket bolt and position the harness aside. ^ To install, tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7527 5. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. ^ To install, tighten to 80 Nm (59 lb-ft). 6. Remove and discard the shock absorber lower nut and bolt. ^ To install, tighten to 475 Nm (350 lb-ft). 7. Remove the 3 integrated wheel end bolts. ^ To install, tighten to 15 Nm (11 lb-ft). 8. Remove and discard the upper ball joint nut. ^ To install, tighten to 115 Nm (85 lb-ft). 9. NOTE: Be sure not to damage the ball joint boot when installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 10. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 11. CAUTION: Make sure to use the special tool when separating the lower ball joint from the knuckle to prevent damage to the ball joint boot. Using the special tool, separate the lower ball joint from the wheel knuckle and remove the wheel knuckle. 12. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. ^ To install, tighten to 17 Nm (13 lb-ft). 13. CAUTION: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7528 To install, reverse the removal procedure. 14. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Purging Special Tool(s) Material CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power steering purge procedure must be carried out prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the power steering pump reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. 3. Tightly insert the stopper of the vacuum pump into the reservoir. 4. Start the engine. 5. Install the vacuum pump, apply vacuum and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 6. If equipped with Hydro-Boost, apply the brake pedal twice. 7. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop-to-stop 10 times. 8. Stop the engine. 9. Release the vacuum and remove the vacuum pump. 10. CAUTION: Do not overfill the reservoir. Fill the reservoir. ^ Use approved transmission fluid. 11. Start the engine. 12. Install the vacuum pump. Apply and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 13. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop-to-stop 10 times. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7533 14. Stop the engine, release the vacuum and remove the vacuum pump. 15. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and install the reservoir cap. 16. Visually inspect the power steering system for leaks. 17. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and visually inspect the power steering system for leaks. 18. Install the reservoir cap. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7538 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 7539 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89L (2 qt) of power steering fluid. For steering system fluid capacity, refer to Specifications. 10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the bellows boot clamp from the steering gear bellows boots to inspect for internal steering gear leaks. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation A/C CONDENSER/POWER STEERING COMBO COOLER NOTE: Installation of a new receiver/drier cartridge 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 cartridge. The A/C condenser/power steering combo cooler is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core. The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation > Page 7543 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler 1. The power steering fluid cooler is integral to the A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. Remove the upper air deflector 1 Remove the 10 upper air deflector pushpin-type retainers. 2 Remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 7547 2. Remove the air cleaner element. 3. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 4. Release the clamp and disconnect the power steering return hose from the power steering fluid reservoir. 5. Release the clamp and disconnect the power steering pump supply hose from the power steering fluid reservoir. 6. Remove the power steering fluid reservoir bolt and reservoir. ^ To install, tighten to 6 Nm (53 lb-in). 7. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose 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. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the upper air deflector. 1 Remove the 10 upper air deflector pushpin-type retainers. 2 Remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 7552 3. Remove the air cleaner outlet pipe. 4. Release the clamp and disconnect the power steering return hose from the power steering fluid cooler. 5. Release the power steering return hose from the cooling fan shroud clips. 6. Release the lower cooling fan shroud tab and rotate the shroud upward. 7. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering return line from the power steering gear. ^ To install, tighten to 23 Nm (17 lb-ft). ^ Discard the steering line O-ring seals. 9. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 7553 Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 7554 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 7555 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. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. 1. Remove the power steering pump pulley. 2. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 lb-ft). 3. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. Disconnect the power steering pressure line-to-power steering pump fitting. ^ Discard the Teflon O-ring seal. ^ To install, tighten to 65 Nm (48 lb-ft). 4. Remove the power steering pressure line bracket-to-crossmember bolt. ^ To install, tighten to 6 Nm (53 lb-in). 5. Remove the power steering pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 7556 6. NOTE: A new O-ring seal must be installed any time the power steering line is disconnected from the power steering gear. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering line. ^ Discard the O-ring seals. ^ To install, tighten to 23 Nm (17 lb-ft). 7. NOTE: A new O-ring seal must be installed any time the power steering line is disconnected from the power steering gear. NOTE: A new Teflon O-ring seal must be installed any time the power steering line is disconnected from the power steering pump. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring on the pressure line-to-pump fitting and pressure line-to-steering gear. 8. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7561 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: A new Teflon O-ring seal must be installed any time the line is disconnected from the power steering pump. 1. Remove the power steering pump pulley. 2. Release the clamp and disconnect the supply hose from power steering pump. 3. Remove the power steering pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7562 4. NOTE: A new Teflon O-ring seal must be installed any time the line is disconnected from the power steering pump. Disconnect the power steering pressure line-to-power steering pump fitting. ^ Discard the Teflon O-ring seal. ^ To install, tighten to 65 Nm (48 lb-ft). 5. Remove the 3 bolts and the power steering pump. ^ To install, tighten to 25 Nm (18 lb-ft). 6. NOTE: A new Teflon O-ring seal must be installed any time the line is disconnected from the power steering pump. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring on the pressure line-to-pump fitting. 7. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7563 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Special Tool(s) Removal 1. With the vehicle in NEUTRAL , position it on a hoist. 2. Remove the upper air deflector 1 Remove the 10 upper air deflector pushpin-type retainers. 2 Remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7564 3. Remove the air cleaner outlet pipe. 4. Remove the 2 upper cooling fan shroud bolts. 5. Release the lower cooling fan shroud tab and rotate the shroud upwards. 6. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the power steering pump pulley. 7. Position the cooling fan shroud assembly upward to gain clearance to install the special tool. 8. 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. CAUTION: Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is 1 paint mark or none at all, use a paint pencil to mark the web area of the pulley near the hub. Using the special tool, install the power steering pump pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7565 2. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt to the power steering pump pulley. 3. Lower the cooling fan shroud assembly. ^ Release the lower cooling fan shroud tab, rotate shroud downward. 4. Install the 2 upper cooling fan shroud bolts. ^ Tighten to 3 Nm (27 lb-in). 5. Install the air cleaner outlet pipe. 6. Install the upper air deflector and the 10 pushpin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 7571 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7575 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 7585 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7591 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7592 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7593 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7594 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7595 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7596 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7597 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7598 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7599 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7600 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7601 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7602 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7603 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area Steering Column Bearing: Customer Interest Interior - Tick/Creak From Instrument Panel Area TSB 08-17-4 09/01/08 TICKING OR CREAKING SOUND - INSTRUMENT PANEL AREA FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a ticking or creaking sound coming from the instrument panel area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To determine if column lower bearing is source of noise, do the following: 1. Park vehicle on level ground with steering wheel in straight ahead 12 o'clock position and engine off. 2. From underneath instrument panel, grasp lower intermediate shaft U-joint and apply light pressure up and down to load the lower column bearing. 3. Listen for any ticking or creaking sound while applying pressure up and down. 4. If no noise is heard at 12 o'clock wheel position, repeat Step 3 at the 3, 6, and 9 o'clock wheel positions. 5. If noise is detected, use chassis ears to confirm noise is coming from plastic steering column lower bearing. Noise will be loudest with chassis ears attached to the plastic tone ring disc, which is part of bearing. a. If the noise is confirmed go to Step 6. b. If not confirmed this procedure does not apply. Refer to Workshop Manual (WSM), Section 100-04. NOTE COMPLETE DISASSEMBLY OF STEERING COLUMN IS NOT REQUIRED. FOLLOW THE WORKSHOP MANUAL STEPS NECESSARY TO REMOVE ONLY THE LOWER STEERING COLUMN BEARING. 6. Replace steering column lower bearing following WSM, Section 211-04. 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 081704A 2007-2008 Expedition, 1.2 Hrs. Navigator: Replace Steering Column Lower Bearing. Includes Time to Remove and Install Steering column.(Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area > Page 7612 Use With 3514A) DEALER CODING CONDITION BASIC PART NO. CODE 3A510 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area Steering Column Bearing: All Technical Service Bulletins Interior - Tick/Creak From Instrument Panel Area TSB 08-17-4 09/01/08 TICKING OR CREAKING SOUND - INSTRUMENT PANEL AREA FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a ticking or creaking sound coming from the instrument panel area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To determine if column lower bearing is source of noise, do the following: 1. Park vehicle on level ground with steering wheel in straight ahead 12 o'clock position and engine off. 2. From underneath instrument panel, grasp lower intermediate shaft U-joint and apply light pressure up and down to load the lower column bearing. 3. Listen for any ticking or creaking sound while applying pressure up and down. 4. If no noise is heard at 12 o'clock wheel position, repeat Step 3 at the 3, 6, and 9 o'clock wheel positions. 5. If noise is detected, use chassis ears to confirm noise is coming from plastic steering column lower bearing. Noise will be loudest with chassis ears attached to the plastic tone ring disc, which is part of bearing. a. If the noise is confirmed go to Step 6. b. If not confirmed this procedure does not apply. Refer to Workshop Manual (WSM), Section 100-04. NOTE COMPLETE DISASSEMBLY OF STEERING COLUMN IS NOT REQUIRED. FOLLOW THE WORKSHOP MANUAL STEPS NECESSARY TO REMOVE ONLY THE LOWER STEERING COLUMN BEARING. 6. Replace steering column lower bearing following WSM, Section 211-04. 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 081704A 2007-2008 Expedition, 1.2 Hrs. Navigator: Replace Steering Column Lower Bearing. Includes Time to Remove and Install Steering column.(Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area > Page 7618 Use With 3514A) DEALER CODING CONDITION BASIC PART NO. CODE 3A510 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Motor > Component Information > Diagrams C227 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Motor > Component Information > Diagrams C227 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Switch > Component Information > Diagrams C2250 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump will occur. Rotate the steering wheel to the RH stop, then turn the steering wheel 90 degrees back from that position. Slowly turn the steering wheel back and forth approximately 1/12 of a full turn. 4. Turn the steering wheel another 90 degrees. Slowly turn the steering wheel back and forth approximately 1/12 of a full turn. 5. Repeat the test with the power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, purge the power steering system. If a loud grunt or strong shudder still exists, check the power steering lines/hoses for restrictions or damage and repair as necessary. If the lines/hoses are OK, install a new steering gear. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7634 Steering Gear: Service and Repair Steering Gear Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7635 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not allow the steering column shaft to rotate while disconnected from the gear or damage to the clockspring can occur. if there is evidence that the steering column shaft has rotated, the clockspring must be recentered. Hold the steering wheel in the straight ahead position using a suitable holding device. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7636 3. Remove and discard the tie-rod end nuts. 4. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, disconnect the tie-rod ends from the wheel knuckles. 5. Release the lower cooling fan shroud tab and rotate the shroud upward. 6. Remove the 2 bolts and the oil drip shield. 7. CAUTION: Do not allow the steering column shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the steering column shaft has rotated, the clockspring must be removed and recentered. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7637 Remove the steering column shaft-to-steering gear bolt and disconnect the steering column shaft from the steering gear. 8. CAUTION: New O-ring seals must be installed any time the lines are disconnected from the steering gear. Remove the steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering lines. ^ Discard the O-rings seals. 9. Remove the 2 steering gear bolts and remove the steering gear. ^ Discard the bolts. Installation 1. CAUTION: Make sure the LH steering gear bushing is seated correctly or premature failure of the steering gear can occur. The RH side bushing does not have locking tabs. Position the steering gear and install the 2 steering gear bolts. ^ Tighten to 440 Nm (325 lb-ft). 2. Connect the steering column shaft and install the bolt. ^ Tighten to 30 Nm (22 lb-ft). 3. NOTE: New O-ring seals must be installed any time the line is disconnected from the power steering gear. Connect the steering lines, rotate the clamp plate and install the clamp plate bolt. ^ Tighten to 23 Nm (17 lb-ft). 4. Install the oil drip shield and the 2 bolts. ^ Tighten to 11 Nm (8 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7638 5. Release the lower cooling fan shroud tab and rotate the shroud downward. 6. CAUTION: Make sure that the tie-rod end boots are seated correctly on the tie-rod ends or premature failure can occur. Connect the tie-rod ends to the wheel knuckles and install the nuts. ^ Tighten to 115 Nm (85 lb-ft). 7. Fill the power steering system. 8. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair Steering Shaft: Service and Repair Steering Column Shaft Removal and Installation 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Place the steering wheel and the front wheels in the straight-ahead position. Turn the ignition switch to the OFF position and remove the key. 3. 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 clock spring must be recentered. Remove the bolt and disconnect the steering column shaft from the steering column. ^ Discard the bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 4. Remove the bolt and disconnect the upper intermediate shaft from the lower intermediate shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 7642 ^ Discard the bolt. ^ To install, tighten to 48 Nm (35 lb-ft). 5. Remove the 2 bolts, the dash seal and the upper intermediate shaft. ^ To install, tighten to 12 Nm (9 lb-ft). 6. Remove the bolt and disconnect the lower steering column shaft from the steering gear. ^ Discard the bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 7. CAUTION: New steering column shaft bolts must be installed. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 7651 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 (2007)) 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 (2007)) 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 7657 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7658 View 151-17 (Steering Wheel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left Steering Wheel: Diagrams Steering Wheel Switch, Left C2366 C2998 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left > Page 7661 Steering Wheel: Diagrams Steering Wheel Switch, Right C2367 C2999 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Page 7662 Steering Wheel: Service and Repair Steering Wheel Removal and Installation 1. Remove the driver air bag module. 2. Turn the steering wheel to the straight-ahead position. 3. Remove and discard the steering wheel bolt. ^ To install, tighten to 40 Nm (30 lb-ft). 4. Remove the steering wheel while routing the wires from the clockspring through the steering wheel. 5. NOTE: A new steering wheel bolt must be installed. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7666 Removal CAUTION: The steering gear bellows boots and clamps are designed to provide an airtight seal and protect the internal components of the steering gear. If the seal is not airtight, the vacuum generated during turning will draw water and contamination into the gear, causing premature damage. CAUTION: Zip ties do not produce an airtight seal and must not be used. CAUTION: The inner tie-rod ball joint grease is not compatible with water. Contamination trapped in the grease will degrade the life of the joint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7667 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 it on a hoist. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the tie-rod end nut. 4. CAUTION: Careful not to damage the tie-rod boot when installing the special tool. Using the special tool, disconnect the tie-rod end from the wheel knuckle. 5. NOTE: Count the number of turns required to remove the tie-rod end for reference during installation. Remove the tie-rod end. 6. Remove the tie-rod end jam nut. 7. NOTE: New bellows boot clamps must be installed. Remove and discard the inner and outer bellows boot clamp. 8. Remove the steering gear bellows boot. 9. CAUTION: Place the steering gear at the center position. Use a 1-1/16 inch 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: If repairing the RH side, it will be necessary to pull back the LH inner tie-rod boot to hold the steering gear. NOTE: An assistant may be needed for removal of the RH inner tie rod. Using the special tool, remove the inner tie rod. 10. 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. Installation 1. Using the special tool, install the inner tie rod. ^ Tighten to 120 Nm (89 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7668 2. NOTE: Apply steering gear grease to the steering gear bellows boot groove in the inner tie rod. NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear housing bead and the groove in the inner tie rod. Install the steering gear bellows boot. 3. Using the special tool, install a new inner bellows boot clamp. 4. NOTE: Make sure the end of the steering gear bellows is positioned between the 2 grooves on the inner tie rod or an internal leak can result. Install a new outer bellows boot clamp. 5. Thread the tie-rod end jam nut onto the inner tie rod. 6. NOTE: Install the tie-rod end the same number of turns as recorded during the removal. Install the tie-rod end to the inner tie rod. 7. CAUTION: Make sure that the tie-rod end boots are seated correctly on the tie-rod ends or premature failure can occur. Connect the tie-rod end to the wheel knuckle and install a new tie-rod end nut. ^ Tighten to 115 Nm (85 lb-ft). 8. Tighten the tie-rod end jam nut. ^ Tighten to 103 Nm (76 lb-ft). 9. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball joint deflection Lower ................................................................................................................................................... .............................................. 0-0.8 mm (0-0.032 in.) Upper ............................................................... .................................................................................................................................. 0-0.2 mm (0-0.008 in.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7673 Ball Joint: Testing and Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. 2. WARNING: If equipped with vehicle dynamic suspension, the system must be disabled prior to lifting the 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. 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. ^ If the deflection meets the specification, continue with the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7674 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Ball Joint: Service and Repair Front Ball Joint - Lower Special Tool(s) Removal and Installation 1. Remove the wheel knuckle. 2. Remove and discard the lower ball joint snap ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front > Page 7677 3. Using the special tools, remove the lower ball joint. 4. CAUTION: Do not damage the lower ball joint boot when installing the special tool. NOTE: Clean and inspect the lower arm lower ball joint bore for damage before installing a new ball joint. NOTE: Make sure the lower ball joint is fully seated in the lower control arm. NOTE: Make sure the new lower ball joint snap ring is fully seated. NOTE: Always install new nuts and cotter pins. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front > Page 7678 Ball Joint: Service and Repair Rear Ball Joint - Lower Special Tool(s) Removal 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front > Page 7679 1. Remove the wheel knuckle. 2. Remove and discard the ball joint snap ring. 3. Using the special tools, remove the ball joint. Installation 1. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the ball joint bore for bore damage before installing a new ball joint. Using the special tool, install the ball joint. 2. NOTE Always use a new ball joint snap ring. Install a new snap ring. 3. Install the wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. CAUTION: Do not tighten the lower shock nut, lower arm forward nut or lower arm rearward nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. Remove the wheel knuckle. 2. 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 80 Nm (59 lb-ft). 3. Remove the lower arm rearward nut and bolt. ^ Discard the nut. ^ To install, tighten to 350 Nm (258 lb-ft). 4. Remove the lower arm forward nut and bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7684 ^ Discard the nut. ^ To install, tighten to 350 Nm (258 lb-ft). 5. Remove the shock absorber lower nut, bolt and the lower arm. ^ Discard the shock absorber lower nut. ^ To install, tighten to 475 Nm (350 lb-ft). 6. CAUTION: Do not tighten the lower shock nut, lower arm forward nut or lower arm rearward nut 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. 7. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7685 Control Arm: Service and Repair Rear Upper Arm Upper Arm 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 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. CAUTION: Do not tighten the upper arm-to-frame bushing until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the upper arm-to-wheel knuckle nut. ^ To install, tighten to 103 Nm (76 lb-ft). 3. Remove and discard the upper arm-to-frame bolt, washer, camber set shim and flagnut. ^ To install, tighten to 300 Nm (221 lb-ft). 4. Remove the upper arm. 5. CAUTION: Do not tighten the upper arm-to-frame bushing until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7686 To install, reverse the removal procedure. 6. Check and, if necessary, adjust the rear alignment. Lower Arm Lower Arm Special Tool(s) Removal 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. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. CAUTION: Do not tighten the lower arm-to-frame bolt or shock absorber lower nut until the installation procedure is complete and the Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7687 weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, disconnect the air suspension height sensor connecting link from the lower arm. 3. Remove and discard the shock absorber lower bolt and flagnut. 4. Remove and discard the lower arm-to-frame bolt and flagnut. 5. Remove and discard the lower ball joint nut. 6. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the lower ball joint from the wheel knuckle. 7. Swing the lower arm to the rear of the vehicle and remove the lower arm. Installation 1. Position the lower arm ball joint onto the wheel knuckle and install the lower ball joint nut. ^ Tighten to 150 Nm (111 lb-ft). 2. CAUTION: Do not tighten the lower arm-to-frame bolt at this time. Install the lower arm-to-frame bolt and flagnut. ^ Snug the bolt to 50 Nm (37 lb-ft). 3. CAUTION: Do not tighten the shock absorber lower nut at this time. Position the lower arm and install a new shock absorber lower bolt and nut. 4. Lower the vehicle so that the weight of the vehicle is on the wheel and tire assemblies. 5. Tighten the lower arm-to-frame bolt to 300 Nm (221 lb-ft). 6. Tighten the shock absorber lower bolt to 475 Nm (350 lb-ft). 7. If equipped, connect the air suspension height sensor connecting link to the lower arm. 8. Check and, if necessary, align the rear end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember - Exploded View Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate fasteners and skid plate. 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Page 7692 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: - Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. - The crossmember nuts are installed on the crossmember bolts facing the front of the vehicle. Remove the 4 transmission crossmember bolts (2 each side) and the transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7696 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 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. CAUTION: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. CAUTION: When servicing the lower shock nut, take care not to damage the stabilizer link. 1. Remove the wheel bearing and wheel hub. 2. Remove and discard the tie-rod end nut. ^ To install, tighten to 115 Nm (85 lb-ft). 3. Using the special tool, separate the tie-rod end from the wheel knuckle. 4. Remove the wheel speed sensor harness bracket bolt and position the harness aside. ^ To install, tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7697 5. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. ^ To install, tighten to 80 Nm (59 lb-ft). 6. Remove and discard the shock absorber lower nut and bolt. ^ To install, tighten to 475 Nm (350 lb-ft). 7. Remove the 3 integrated wheel end bolts. ^ To install, tighten to 15 Nm (11 lb-ft). 8. Remove and discard the upper ball joint nut. ^ To install, tighten to 115 Nm (85 lb-ft). 9. NOTE: Be sure not to damage the ball joint boot when installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 10. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 11. CAUTION: Make sure to use the special tool when separating the lower ball joint from the knuckle to prevent damage to the ball joint boot. Using the special tool, separate the lower ball joint from the wheel knuckle and remove the wheel knuckle. 12. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. ^ To install, tighten to 17 Nm (13 lb-ft). 13. CAUTION: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7698 To install, reverse the removal procedure. 14. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing Rear Knuckle: Service and Repair Wheel Knuckle Bushing Wheel Knuckle Bushing Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7703 Removal 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. CAUTION: Do not tighten the upper trailing arm-to-knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the upper trailing arm-to-wheel knuckle bolt. ^ Position the upper trailing arm upward to access the wheel knuckle bushing. 3. Using the special tools, remove the wheel knuckle bushing. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7704 1. Clean and inspect the wheel knuckle bushing bore for damage or excessive wear. 2. Position the new wheel knuckle bushing with the larger void facing towards the upper trailing arm. 3. Install the special tools. 4. CAUTION: Do not use the forward forcing screw nut to install the bushing. The forward forcing screw nut is only used to properly position and align the bushing for installation. Hand tighten the forward forcing screw nut to align the bushing with the rearward side of the wheel knuckle bore. 5. CAUTION: Use the rearward forcing screw nut to install the bushing or damage to the bushing and/or the wheel knuckle bushing bore can result. Tighten the rearward forcing screw nut and install the bushing until it is centered in the wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7705 6. NOTE: After installing the wheel knuckle bushing, make sure to measure the bushings position in the wheel knuckle bore. The measurement from the bushings outer metal surface to the machined face surface of knuckle bore should be 2.54 mm (0.16 in) +/- 0.25 mm (0.01 in). If necessary, use the special tool to adjust the bushing position in the wheel knuckle bushing bore. 7. CAUTION: Do not tighten the upper trailing arm-to-knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Connect the upper trailing arm to the wheel knuckle. ^ Tighten the bolt to 250 Nm (184 lb-ft). 8. Remove the jack stand from under the lower arm. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7706 Rear Knuckle: Service and Repair Wheel Knuckle Wheel Knuckle Special Tool(s) 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 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. CAUTION: Do not tighten the upper arm-to wheel knuckle bolt or the toe link-to-wheel knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7707 1. Remove the wheel bearing and wheel hub assembly. 2. Remove the parking brake shoes. 3. Remove the brake disc shield. 4. Compress the spring and depress the retaining tabs and detach the parking brake cable from the wheel knuckle. 5. Remove and discard the upper arm-to-wheel knuckle nut. ^ To install, tighten to 103 Nm (76 lb-ft). 6. Using the special tool, separate the upper arm from the wheel knuckle. 7. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 8. Using the special tool, separate the lower ball joint from the wheel knuckle. 9. Remove and discard the 2 bolts and disconnect the lower trailing arm from the wheel knuckle. ^ To install, tighten to 103 Nm (76 lb-ft). 10. CAUTION: Do not tighten the toe link-to- wheel knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Remove and discard the bolt and disconnect the toe link from the wheel knuckle. ^ To install, tighten to 225 Nm (166 lb-ft). 11. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Using the hex hold feature, remove and discard the stabilizer bar link nut and disconnect the link from the wheel knuckle. ^ To install, tighten to 63 Nm (46 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 7708 12. CAUTION: Do not tighten the upper arm-to wheel knuckle until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Remove the upper trailing arm-to-wheel knuckle bolt and the wheel knuckle. ^ Discard the bolt. ^ To install, tighten to 250 Nm (184 lb-ft). 13. CAUTION: Do not tighten the upper arm-to wheel knuckle bolt or the toe link-to wheel knuckle bolt 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. CAUTION: Do not tighten the toe link-to-frame cam bolt or toe link-to-wheel knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the cam bolt and cam washer positions. 3. Remove and discard the bolt and washer. ^ To install, tighten to 225 Nm (166 lb-ft). 4. Remove the toe link-to-frame cam bolt, cam washer and nut. ^ To install, tighten to 275 Nm (203 lb-ft). 5. Remove the toe link. 6. CAUTION: Do not tighten the toe link-to-frame cam bolt or the toe link-to-wheel knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. NOTE: Using the index marks made in Step 5, transfer the marks onto the new cam bolt and cam washer. Use these index marks when installing the toe link. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 7712 To install, reverse the removal procedure. 7. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7717 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7718 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7719 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 7723 Suspension Control Module: Diagrams C2131A C2131B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 7724 Suspension Control Module: Service and Repair Air Suspension 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. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 lb-in). 4. 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 LH and RH ride height sensors are calibrated and a pneumatic test is carried out. For additional information, refer to Vehicle Dynamic Suspension Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 7729 RH Side Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the senor harness from the sensor bracket. 3. Disconnect the sensor electrical connector. 4. Disconnect the sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 sensor bolts. ^ To install, tighten to 11 Nm (8 lb-ft). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7733 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front Stabilizer Bar and Link 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the nut. Remove and discard the 2 stabilizer bar link upper nuts. ^ To install, tighten to 80 Nm (59 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7739 3. CAUTION: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the 2 stabilizer bar link lower nuts and remove the 2 stabilizer bar links. ^ To install, tighten to 80 Nm (59 lb-ft). 4. Remove the 4 stabilizer bar bracket nuts, brackets and the stabilizer bar. ^ Discard the nuts. ^ To install, tighten to 55 Nm (41 lb-ft). 5. Remove and discard the stabilizer bracket bolt plates. 6. NOTE: Make sure the stabilizer bar bushing upset is installed into the bracket groove. Inspect and, if necessary, install new stabilizer bar bushings. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7740 Stabilizer Link: Service and Repair Rear Stabilizer Bar and Link 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. Remove the 4 stabilizer bar link nuts and the links. ^ Discard the nuts. ^ To install, tighten to 63 Nm (46 lb-ft). 3. Remove the 4 stabilizer bar bracket nuts, the 2 stabilizer bar brackets and the stabilizer bar. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7741 ^ Discard the nuts. ^ To install, tighten to 48 Nm (35 lb-ft). 4. NOTE: Inspect and, if necessary, install new bushings. NOTE: The rear stabilizer must be installed with the center hump facing down. NOTE: The rear stabilizer bar bushings must be installed outboard of the upset rings on the stabilizer bar. NOTE: The stabilizer bar link stone shields must be installed on the stabilizer bar attachment point. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 in) 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > Customer Interest for Air Spring: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Air Spring: Customer Interest Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Spring: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Air Spring: All Technical Service Bulletins Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > Page 7759 Air Spring: Service and Repair Air Shock Absorber - Rear Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > Page 7760 Removal and Installation 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > Page 7761 1. Using the scan tool, vent the appropriate air spring. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the lower arm. 4. Disconnect the air spring solenoid 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. Remove and discard the 3 shock upper nuts. ^ To install, tighten to 40 Nm (30 lb-ft). 7. Remove the air shock absorber. 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 45 Nm (33 lb-ft). 9. 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. 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 2 retainer screws and the upper mount. ^ Discard the screws. 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: Make sure that all seals are clean and free of debris. NOTE: Apply a thin coat of grease to the new O-ring seals. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams C1179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 7765 Compressor/Pump: Service and Repair Air Suspension Compressor Removal and Installation 1. Remove the inner fender splash shield. 2. Disconnect the air line from the compressor drier. ^ Compress the quick connect lock ring inward, then pull the line outward from the air drier. 3. Disconnect the air compressor air intake hose. 4. Disconnect the air compressor electrical connector. 5. Remove the 3 air compressor bracket bolts and remove the air compressor and bracket assembly. ^ To install, tighten to 15 Nm (11 lb-ft). 6. NOTE: When installing the air lines, make sure the white inner air line is fully inserted into the fitting for correct installation. NOTE: Make sure that there are no objects trapped under or on the bracket. Make sure that the air compressor is not in contact with any surrounding components that could cause vibration noises. NOTE: Make sure that the air compressor moves freely in the rubber isolators. Make sure that the bracket has no deformations that could cause the 3 rubber isolators to load against each other. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7769 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7770 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7771 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations Damping Control Actuator: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations > Page 7775 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Rear C4044 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Rear > Page 7778 C4045 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Customer Interest for Level Control Solenoid Valve: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Level Control Solenoid Valve: Customer Interest Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Level Control Solenoid Valve: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Level Control Solenoid Valve: All Technical Service Bulletins Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Page 7792 Level Control Solenoid Valve: Service and Repair Air Spring Solenoid Valve Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Page 7793 Removal and Installation 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. 1. If the air spring solenoid valve is functional, use the scan tool to vent the appropriate air spring(s). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Disconnect the air spring solenoid valve electrical connector. 4. Disconnect the air line at the air valve. ^ Compress the orange quick connect lock ring, then pull downward on the air supply line. 5. 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. 6. 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. 7. NOTE: Inspect the air spring O-ring for damage and install a new O-ring as necessary. Lightly lubricate the solenoid seal area with silicone grease. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. NOTE: When installing the air spring solenoid, make sure that the electrical connector is positioned away from the air spring. NOTE: When installing the air lines, make sure the air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 7797 RH Side Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the senor harness from the sensor bracket. 3. Disconnect the sensor electrical connector. 4. Disconnect the sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 sensor bolts. ^ To install, tighten to 11 Nm (8 lb-ft). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 7801 Suspension Control Module: Diagrams C2131A C2131B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 7802 Suspension Control Module: Service and Repair Air Suspension 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. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 lb-in). 4. 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 LH and RH ride height sensors are calibrated and a pneumatic test is carried out. For additional information, refer to Vehicle Dynamic Suspension Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle Suspension Strut / Shock Absorber: Customer Interest Suspension - Front/Rear Suspension Squeak/Rattle TSB 08-19-11 09/29/08 SQUEAK / RATTLE FRONT OR REAR SUSPENSION FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a squeak noise from the front or rear suspension. The source of the noise may be the lower shock attachment bolt and nut. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use chassis ears to confirm the noise is coming from the shock to lower control arm attachment nut and bolt. 2. If confirmed, loosen the nut and bolt and re-torque to the 350 lb-ft (475 N.m) specification in the Workshop Manual (WSM), Section 204. 3. Retest for the noise. If concern still exists, replace the shock, nut and attaching bolt per WSM, Section 204. 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 081911A 2007-2008 Expedition, 1.3 Hrs. Navigator: Diagnosis, Includes Time To Install Chassis Ears, and Torque Fasteners. Includes All Necessary Road Tests, This Labor Operation Can Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle > Page 7811 Be Claimed With Any Of the Operations In This Article (Do Not Use With 18124A, 18125A, 5649A) 081911B 2007-2008 Expedition, 0.7 Hr. Navigator: Replace One Front Shock This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911C 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace Both Front Shocks This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911D 2007-2008 Expedition, 0.9 Hr. Navigator: Replace One Rear Shock This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A 18125A, 5649A) 081911E 2007-2008 Expedition, 1.7 Hrs. Navigator: Replace Both Rear Shocks This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A, 18125A, 5649A) DEALER CODING CONDITION BASIC PART NO. CODE 18125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front/Rear Suspension Squeak/Rattle TSB 08-19-11 09/29/08 SQUEAK / RATTLE FRONT OR REAR SUSPENSION FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a squeak noise from the front or rear suspension. The source of the noise may be the lower shock attachment bolt and nut. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use chassis ears to confirm the noise is coming from the shock to lower control arm attachment nut and bolt. 2. If confirmed, loosen the nut and bolt and re-torque to the 350 lb-ft (475 N.m) specification in the Workshop Manual (WSM), Section 204. 3. Retest for the noise. If concern still exists, replace the shock, nut and attaching bolt per WSM, Section 204. 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 081911A 2007-2008 Expedition, 1.3 Hrs. Navigator: Diagnosis, Includes Time To Install Chassis Ears, and Torque Fasteners. Includes All Necessary Road Tests, This Labor Operation Can Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle > Page 7817 Be Claimed With Any Of the Operations In This Article (Do Not Use With 18124A, 18125A, 5649A) 081911B 2007-2008 Expedition, 0.7 Hr. Navigator: Replace One Front Shock This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911C 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace Both Front Shocks This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911D 2007-2008 Expedition, 0.9 Hr. Navigator: Replace One Rear Shock This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A 18125A, 5649A) 081911E 2007-2008 Expedition, 1.7 Hrs. Navigator: Replace Both Rear Shocks This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A, 18125A, 5649A) DEALER CODING CONDITION BASIC PART NO. CODE 18125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Shock Absorber and Spring Assembly 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 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 lower arm. 2. Remove and discard the upper mount nuts. ^ To install, tighten to 40 Nm (30 lb-ft). 3. Remove the shock absorber and spring assembly. 4. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 7. NOTE: For reference during assembly, index the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7820 5. While holding the shock rod, remove the nut and washer. ^ Remove the shock absorber. ^ Discard the nut. ^ To install, tighten to 56 Nm (41 lb-ft). 6. Remove the upper mount, dust boot and insulator. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper Trailing Arm: Service and Repair Trailing Arm - Upper Trailing Arm - Upper Removal and Installation 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. CAUTION: Do not tighten the upper arm-to-frame bolt or upper arm-to-knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the upper trailing arm-to-wheel knuckle bolt. ^ To install, tighten to 250 Nm (184 lb-ft). 3. Remove and discard the upper trailing arm-to-frame bolt and flagnut. ^ To install, tighten to 275 Nm (203 lb-ft). 4. NOTE: After removal of the upper trailing arm, inspect the knuckle bushing for excessive wear or damage and replace if necessary. Remove the upper trailing arm. 5. CAUTION: Do not tighten the upper arm-to-frame bolt or upper arm-to-knuckle bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper > Page 7825 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper > Page 7826 Trailing Arm: Service and Repair Trailing Arm - Lower Trailing Arm - Lower 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 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. CAUTION: Do not tighten the lower trailing arm-to-frame bolt until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 lower trailing arm-to-wheel knuckle bolts. ^ To install, tighten to 103 Nm (76 lb-ft). 3. Remove and discard the lower trailing arm-to-frame bolt and flagnut. ^ To install, tighten to 275 Nm (203 lb-ft). 4. Remove the lower trailing arm. 5. CAUTION: Do not tighten the lower trailing arm-to-frame bolt 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7831 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. Disconnect the wheel speed sensor electrical connector. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the wheel speed sensor harness bolt and detach the harness from the retainers. ^ To install, tighten to 12 Nm (9 lb-ft). 4. 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 brake caliper and anchor plate assembly aside. ^ Support the brake caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the halfshaft nut dust cap. 7. Remove and discard the halfshaft nut. ^ To install, tighten to 27 Nm (20 lb-ft). 8. Remove the 4 wheel bearing and wheel hub bolts and the wheel hub. ^ To install, tighten to 185 Nm (136 lb-ft). 9. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 18 Nm (13 lb-ft). 10. CAUTION: If the original wheel bearing and wheel hub is being installed, install a new wheel hub O-ring seal. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7832 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. ^ To install, tighten to 300 Nm (221 lb-ft). 3. Using a suitable hub puller, separate the outboard CV joint from the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7833 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 190 Nm (140 lb-ft). 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 wheel bearing and wheel hub bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake disc shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 lb-ft). 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. ^ To install, tighten to 18 Nm (13 lb-ft). 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Front Front Axle nut....................................................................................................................................... ......................................................... 27 Nm (20 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 7839 Axle Nut: Specifications Rear Rear axle Nut ....................................................................................................................................... .................................................... 300 Nm (221 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 7843 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Service and Repair > Page 7847 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. - 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. Disable the air suspension system. Refer to Electronic Level Control. Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7852 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. CAUTION: 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. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. LIFTING WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. 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. Disable the air suspension system. Refer to Electronic Level Control. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7853 Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. After the vehicle has been lowered, enable the air suspension system. Refer to Electronic Level Control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 7858 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7861 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7862 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7863 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7864 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7865 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7866 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS 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. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out the following procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire (as necessary). 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions: 1. 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 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB 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 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 7874 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7877 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7878 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7879 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7880 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7881 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7882 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 7891 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 7892 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 7893 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 (2007)) 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 (2007)) 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 7899 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 (2007)) 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 7900 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 (2007)) 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 7901 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7906 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. Disconnect the wheel speed sensor electrical connector. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the wheel speed sensor harness bolt and detach the harness from the retainers. ^ To install, tighten to 12 Nm (9 lb-ft). 4. 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 brake caliper and anchor plate assembly aside. ^ Support the brake caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the halfshaft nut dust cap. 7. Remove and discard the halfshaft nut. ^ To install, tighten to 27 Nm (20 lb-ft). 8. Remove the 4 wheel bearing and wheel hub bolts and the wheel hub. ^ To install, tighten to 185 Nm (136 lb-ft). 9. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 18 Nm (13 lb-ft). 10. CAUTION: If the original wheel bearing and wheel hub is being installed, install a new wheel hub O-ring seal. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7907 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub 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 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. ^ To install, tighten to 300 Nm (221 lb-ft). 3. Using a suitable hub puller, separate the outboard CV joint from the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7908 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 190 Nm (140 lb-ft). 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 wheel bearing and wheel hub bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake disc shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 lb-ft). 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. ^ To install, tighten to 18 Nm (13 lb-ft). 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Front Front Axle nut....................................................................................................................................... ......................................................... 27 Nm (20 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 7914 Axle Nut: Specifications Rear Rear axle Nut ....................................................................................................................................... .................................................... 300 Nm (221 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 7918 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Page 7922 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts............................................................................................................................................ ..................................................... 204 Nm (150 lb-ft) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 7926 Wheel Fastener: Service and Repair Wheel Studs Special Tool(s) 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. 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 (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 7927 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear Air Door Actuator / Motor: Locations Mode Door Actuator, Rear View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7934 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7935 Air Door Actuator / Motor: Locations Blend Door Actuator, Rear View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7936 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7937 View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7938 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7939 Air Door Actuator / Motor: Locations View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7940 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7941 View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7942 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7943 View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7944 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7945 View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7946 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7947 View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Mode Door Actuator, Rear > Page 7948 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator C2278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7951 Air Door Actuator / Motor: Diagrams Blend Door Actuator, Rear C3004 C4342 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7952 C2091 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7953 C2092 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7954 Air Door Actuator / Motor: Diagrams C2278 C3004 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7955 C4342 C2091 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7956 C2092 C3044 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7957 C4341 C289 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Mode Door Actuator > Page 7958 C2363 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Defrost/Panel/Floor Door MODE DOOR ACTUATOR - DEFROST/PANEL/FLOOR DOOR Removal and Installation NOTE: The defrost/panel/floor mode door actuator can be accessed from underneath the LH side of the instrument panel. 1. Disconnect the defrost/panel/floor mode door actuator electrical connector. 2. Remove the 2 defrost/panel/floor mode door actuator screws. 3. Remove the defrost/panel/floor mode door 4. To install, reverse the removal procedure. actuator. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7961 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Air Inlet Door MODE DOOR ACTUATOR - AIR INLET DOOR Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Remove the junction box cover at the RH lower A-pillar. 3. Remove the 3 air inlet mode door actuator screws. 4. Disconnect the air inlet mode door actuator electrical connector. 5. Remove the air inlet mode door actuator. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7962 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH TEMPERATURE BLEND DOOR ACTUATOR - RH Removal and Installation 1. Remove the audio unit. 2. Disconnect the RH temperature blend door actuator electrical connector. 3. Remove the 2 RH temperature blend door actuator screws. 4. Remove the RH temperature blend door actuator. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7963 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH TEMPERATURE BLEND DOOR ACTUATOR - LH Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the 4 floor duct screws. 3. Remove the floor duct. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the 2 LH temperature blend door actuator screws. 6. Remove the LH temperature blend door actuator. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7964 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Defrost/Panel/Floor Door MODE DOOR ACTUATOR - DEFROST/PANEL/FLOOR DOOR Removal and Installation NOTE: The defrost/panel/floor mode door actuator can be accessed from underneath the LH side of the instrument panel. 1. Disconnect the defrost/panel/floor mode door actuator electrical connector. 2. Remove the 2 defrost/panel/floor mode door actuator screws. 3. Remove the defrost/panel/floor mode door 4. To install, reverse the removal procedure. actuator. Mode Door Actuator - Air Inlet Door MODE DOOR ACTUATOR - AIR INLET DOOR Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7965 Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Remove the junction box cover at the RH lower A-pillar. 3. Remove the 3 air inlet mode door actuator screws. 4. Disconnect the air inlet mode door actuator electrical connector. 5. Remove the air inlet mode door actuator. 6. To install, reverse the removal procedure. Temperature Blend Door Actuator - RH TEMPERATURE BLEND DOOR ACTUATOR - RH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7966 Removal and Installation 1. Remove the audio unit. 2. Disconnect the RH temperature blend door actuator electrical connector. 3. Remove the 2 RH temperature blend door actuator screws. 4. Remove the RH temperature blend door actuator. 5. To install, reverse the removal procedure. Temperature Blend Door Actuator - LH TEMPERATURE BLEND DOOR ACTUATOR - LH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7967 Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the 4 floor duct screws. 3. Remove the floor duct. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the 2 LH temperature blend door actuator screws. 6. Remove the LH temperature blend door actuator. 7. To install, reverse the removal procedure. Auxiliary Mode Door Actuator AUXILIARY MODE DOOR ACTUATOR Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7968 Removal and Installation 1. Remove the RH quarter trim panel cup holder. 2. Remove the RH quarter trim panel utility tray. 3. Remove the 3 auxiliary mode door actuator screws. 4. Disconnect the auxiliary mode door actuator electrical connector. 5. Remove the auxiliary mode door actuator. 6. To install, reverse the removal procedure. Auxiliary Mode Door Actuator - Expedition EL, Navigator L AUXILIARY MODE DOOR ACTUATOR - EXPEDITION EL, NAVIGATOR L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7969 Removal and Installation 1. Fold the third row seats fully forward. 2. Remove the RH D-pillar trim panel. 3. Remove the liftgate sill plate. 4. Remove the rear floor cargo space trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7970 5. Position the rear floor cargo space floor trim aside and remove the RH rear quarter trim panel bolt. 6. Remove the RH quarter trim panel utility tray. 7. Detach the 3 rear and 5 upper RH quarter trim panel clips and position the quarter trim panel aside. 8. Disconnect the auxiliary mode door actuator electrical connector. 9. Remove the 2 auxiliary mode door actuator screws. 10. Remove the auxiliary mode door actuator. 11. To install, reverse the removal procedure. Auxiliary Temperature Blend Door Actuator AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7971 Removal and Installation 1. Remove the RH quarter trim panel. 2. Disconnect the auxiliary temperature blend door actuator electrical connector. 3. Remove the 4 auxiliary temperature blend door actuator screws. 4. Remove the auxiliary temperature blend door actuator. 5. To install, reverse the removal procedure. Auxiliary Temperature Blend Door Actuator - Expedition EL, Navigator L AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR - EXPEDITION EL, NAVIGATOR L Removal and Installation 1. Fold the third row seats fully forward. 2. Remove the RH D-pillar trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7972 3. Remove the liftgate sill plate. 4. Remove the rear floor cargo space trim panel. 5. Position the rear floor cargo space floor trim aside and remove the RH rear quarter trim panel bolt. 6. Remove the RH quarter trim panel utility tray. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 7973 7. Detach the 3 rear and 5 upper RH quarter trim panel clips and position the quarter trim panel aside. 8. Disconnect the auxiliary temperature blend door actuator electrical connector. 9. Remove the 2 auxiliary temperature blend door actuator screws. 10. Remove the auxiliary temperature blend door actuator. 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 4 floor duct screws. 3. Remove the floor duct. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7978 Air Duct: Service and Repair Footwell Duct - Rear FOOTWELL DUCT - REAR Removal and Installation All vehicles 1. Remove the front seats. 2. Remove the front floor console. 3. Remove the RH and LH lower cowl trim panels and front door sill plates. Navigator only 4. Remove the upper and lower instrument panel bracket bolts and position the instrument panel bracket aside. - To install, tighten to 9 Nm (80 lb-in). All vehicles 5. Fold back the carpet to completely uncover the rear footwell duct. 6. Remove the 2 rear footwell duct pin-type retainers. 7. Remove the rear footwell duct. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Climate Control Air Register: Service and Repair Climate Control REGISTER Removal and Installation LH register 1. Remove the steering column opening cover. 2. Remove the 4 steering column opening reinforcement bolts and the steering column reinforcement. 3. Remove the LH outer instrument panel trim panel. RH register 4. Lower the glove compartment LH or RH register 5. Working through the instrument panel opening, depress the 2 clips on the sides of the register barrel and tilt the bottom of the register outward to keep the clips from re-engaging. 6. NOTE: RH register shown, LH similar. Using 2 suitable tools, release the clips through the demister nozzle opening and remove the register. Center registers 7. Remove the center instrument panel finish panel. 8. Working through the opening below the audio unit, release the 3 register retaining clips and remove the register. All registers 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Climate Control > Page 7983 Air Register: Service and Repair Auxiliary Climate Control REGISTER Removal and Installation 1. Fabricate a removal tool from a 3.175 mm (0.12 in) diameter rod. 2. Rotate the register with the removal tool to align the retaining ears with the clearance openings and remove the register. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7987 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7988 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest: > 08-9-1 > May > 08 > A/C - Blower Intermittently Inop/Stuck On High Blower Motor: Customer Interest A/C - Blower Intermittently Inop/Stuck On High TSB 08-9-1 05/12/08 EATC BLOWER INTERMITTENTLY INOPERATIVE - STUCK ON HIGH/OFF FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with Electronic Automatic Temperature Control (EATC) may exhibit a condition where the blower motor is inoperative no matter what speed or temp setting or the blower motor is stuck on high speed or off. Cycling the ignition may resume operation. The concern may also occur when using the electrical power point. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Open the glove box and remove Connector C297 from the Heater Blower Controller Module (HBCM). 2. Remove the right front door scuff plate. 3. Remove the right side kick panel to gain access to Ground G200. 4. Cut black/white wire about 8" (20.3 cm) from C297. Strip the end 1/4" (6.3 mm). 5. Obtain pigtail kit and using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector and seal (with shrink tubing) the splice between the 13" (33 cm) pigtail and the black/white wire from C297. 6. Disconnect the existing 14401 single ground eyelet from G200 and cut existing eyelet from the ground wire. 7. Strip 1/4" (6.3 mm) insulation from the 14401 ground wire. 8. Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing) the splice between the 3" (7.6 cm) pigtail and the 14401 wire. 9. Attach the new interlocked ground eyelet to G200. Torque to 11 +/- 1.6 lb-ft (15 +/- 2.3 N.m ) 10. Install the right side kick panel and scuff plate. 11. Replace the HBCM. 12. Attach C297 to the HBCM. 13. Close the glove box door. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest: > 08-9-1 > May > 08 > A/C - Blower Intermittently Inop/Stuck On High > Page 7997 080901A 2007-2008 0.5 Hr. Expedition/Navigator: Replace The HBCM, Includes Time To Isolate Ground (Do Not Use With 19700D8, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 19E624 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-9-1 > May > 08 > A/C - Blower Intermittently Inop/Stuck On High Blower Motor: All Technical Service Bulletins A/C - Blower Intermittently Inop/Stuck On High TSB 08-9-1 05/12/08 EATC BLOWER INTERMITTENTLY INOPERATIVE - STUCK ON HIGH/OFF FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with Electronic Automatic Temperature Control (EATC) may exhibit a condition where the blower motor is inoperative no matter what speed or temp setting or the blower motor is stuck on high speed or off. Cycling the ignition may resume operation. The concern may also occur when using the electrical power point. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Open the glove box and remove Connector C297 from the Heater Blower Controller Module (HBCM). 2. Remove the right front door scuff plate. 3. Remove the right side kick panel to gain access to Ground G200. 4. Cut black/white wire about 8" (20.3 cm) from C297. Strip the end 1/4" (6.3 mm). 5. Obtain pigtail kit and using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector and seal (with shrink tubing) the splice between the 13" (33 cm) pigtail and the black/white wire from C297. 6. Disconnect the existing 14401 single ground eyelet from G200 and cut existing eyelet from the ground wire. 7. Strip 1/4" (6.3 mm) insulation from the 14401 ground wire. 8. Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing) the splice between the 3" (7.6 cm) pigtail and the 14401 wire. 9. Attach the new interlocked ground eyelet to G200. Torque to 11 +/- 1.6 lb-ft (15 +/- 2.3 N.m ) 10. Install the right side kick panel and scuff plate. 11. Replace the HBCM. 12. Attach C297 to the HBCM. 13. Close the glove box door. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-9-1 > May > 08 > A/C - Blower Intermittently Inop/Stuck On High > Page 8003 080901A 2007-2008 0.5 Hr. Expedition/Navigator: Replace The HBCM, Includes Time To Isolate Ground (Do Not Use With 19700D8, 14200A) DEALER CODING CONDITION BASIC PART NO. CODE 19E624 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor: > 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8009 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8010 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8016 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8017 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Auxiliary Blower Motor Blower Motor: Locations Auxiliary Blower Motor View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Auxiliary Blower Motor > Page 8020 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Auxiliary Blower Motor > Page 8021 Blower Motor: Locations Blower Motor View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Auxiliary Blower Motor > Page 8022 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 orientation. 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Blower 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Blower Motor: Connector Views C288 C4106 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 C4334 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 8044 Blower Motor: Description and Operation BLOWER MOTOR The auxiliary climate control system is equipped with a blower motor controlled by the blower motor switch on the front or rear auxiliary control assembly. The auxiliary blower motor is mounted to the auxiliary heater core and evaporator core housing behind the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Blower Motor: Service and Repair Blower Motor BLOWER MOTOR Removal and Installation NOTE: The blower motor vent tube must be completely removed from the blower motor before it can be rotated and disengaged from the heater core and evaporator core housing. 1. Remove the RH lower instrument panel insulator (if equipped). 2. Remove the RH lower A-pillar junction box cover. 3. Position the carpet below the blower motor aside. 4. Release the 2 blower motor vent tube clips and remove the blower motor vent tube. 5. Disconnect the blower motor electrical connector. 6. NOTE: The blower motor will have to be carefully manipulated along the dash panel insulator, and the dash panel insulator will have to be slightly deflected to allow the blower motor to clear the heater core and evaporator core housing. Rotate the blower motor counterclockwise to disengage it from the housing and remove the blower motor. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8047 Blower Motor: Service and Repair Auxiliary Blower Motor AUXILIARY BLOWER MOTOR Removal and Installation All vehicles 1. Remove the RH quarter trim panel. 2. Remove the blower motor. - Disconnect the blower motor electrical connector. - Remove the blower motor screws. - Remove the blower motor. Expedition or Navigator only Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 8048 3. Remove the blower motor wheel. 1 Remove the blower motor wheel clip. 2 Remove the blower motor wheel. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8053 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8054 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8055 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8058 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8059 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8060 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8061 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8062 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8063 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8064 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8066 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8067 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8068 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly Blower Motor Resistor: Locations Auxiliary Blower Motor Resistor Assembly View 151-48 (Auxiliary HVAC - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly > Page 8073 View 151-49 (Auxiliary HVAC - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly > Page 8074 View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor > Page 8077 Blower Motor Resistor: Diagrams Auxiliary Blower Motor Resistor Assembly C4107 C4343 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 8078 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR The blower motor switch varies the blower motor ground circuit resistance by adding or bypassing series resistance in the blower motor resistor. Increased resistance will lower the blower motor speed, and lowered resistance will increase blower motor speed. When the blower motor is in the HIGH position, the blower motor resistor is bypassed. The blower motor resistor is located on the heater core and evaporator core housing near the blower motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Blower Motor Resistor: Service and Repair Blower Motor Resistor BLOWER MOTOR RESISTOR Removal and Installation 1. Disconnect the blower motor resistor electrical connector. 2. Remove the 2 blower motor resistor screws. 3. Remove the blower motor resistor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 8081 Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor AUXILIARY BLOWER MOTOR RESISTOR Removal and Installation NOTE: Expedition or Navigator shown, Expedition EL or Navigator L similar. All vehicles 1. Remove the RH quarter trim panel access panel. Expedition or Navigator only 2. Remove the blower motor resistor. - Disconnect the blower motor resistor electrical connector. - Remove the 2 blower motor resistor screws and the blower motor resistor. Expedition EL or Navigator L only 3. Remove the blower motor resistor. - Disconnect the blower motor resistor electrical connector. - Remove the blower motor resistor screw. - Detach the 2 blower motor resistor clips and remove the blower motor resistor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 8082 All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector positions except OFF. The blower motor switch is mounted to the climate control assembly and can be separately installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 8086 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 8095 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor 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 3 lower steering column cover screws and the lower steering column cover. - Disconnect the electrical connector. 2. Remove the 4 steering column reinforcement bolts and position the steering column reinforcement aside. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the in-vehicle temperature and humidity sensor. 1 Detach the in-vehicle temperature and humidity sensor from the instrument panel finish panel. 2 Disconnect the aspirator hose. 3 Disconnect the in-vehicle temperature and humidity sensor electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 8098 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification Magnetic Clutch Air gap clearance.................................................................................................................................. ...................................0.35-0.65 mm (0.014-0.026 in) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8103 Compressor Clutch: Adjustments AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8104 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8105 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 clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. 5. 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 compressor pulley. 1 Install the special tool. 2 Remove the A/C compressor pulley. 6. Remove the A/C clutch field coil snap ring. 7. Remove the A/C clutch field coil connector screw. 8. 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. Install the A/C clutch field coil snap ring. 5. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Install the A/C compressor pulley. 6. Install the A/C compressor pulley snap ring with the bevel side out. 7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 8. Install the A/C clutch disc and hub. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8106 9. 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 13 Nm (10 lb-ft). 10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. 11. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams C100 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8113 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 is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8114 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8116 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Condenser HVAC: Customer Interest A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8125 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8126 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8127 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Condenser HVAC: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8132 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8133 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8134 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Condenser HVAC: All Technical Service Bulletins A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8140 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8141 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8142 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Condenser HVAC: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8147 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8148 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8149 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area Front Door Weatherstrip: All Technical Service Bulletins Body - Wind Noise From Front Door B-Pillar Area TSB 07-13-4 07/09/07 WIND NOISE AROUND FRONT DOORS - BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-8-6 to clarify vehicle build date. ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience wind noise around the exterior driver and/or passenger doors. This may be most noticeable near the b-pillar area of the door. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE VEHICLE IS BUILT AFTER 12/6/2006, THIS TSB DOES NOT APPLY. PROCEED WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS, REFER TO WORKSHOP MANUAL (WSM), SECTION 100-04. 1. Check the build date of the vehicle. a. If the build date of the vehicle is before 12/1/2006, continue to Step 2. b. If the build date of the vehicle is between 12/1/06 and 12/6/06, continue to Step 3. 2. Verify that the glass run inserts at the b-pillar corner are still in the correct position. (Figure 1) a. First roll down the window and peel back the inner flocked sealing lip in the b-pillar corner. b. There will be two inserts located in the corner. They should both be touching in the corner and at a 90 degree angle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 8155 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 8156 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 8162 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 8163 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 8164 Condenser HVAC: Description and Operation A/C CONDENSER/POWER STEERING COMBO COOLER NOTE: Installation of a new receiver/drier cartridge 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 cartridge. The A/C condenser/power steering combo cooler is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core. The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 8165 Condenser HVAC: Service and Repair CONDENSER CORE Removal and Installation NOTE: Installation of a new receiver/drier cartridge 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 cartridge. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Disconnect the battery cables. 4. Remove the upper radiator sight shield. 5. Remove the RH and LH headlamp assemblies. 6. Remove the air cleaner outlet tube. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 8166 7. Remove the 4 junction box bolts and position the junction box aside. 8. Detach the power steering cooler line clip. 9. Remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (11 lb-ft). 10. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (11 lb-ft). 11. NOTE: RH bolts shown, LH similar. Remove the 2 cooling module and 2 cooling fan shroud bolts. 12. Release the clamps and disconnect the 2 power steering cooler lines from the condenser core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 8167 13. NOTE: LH air deflector shown, RH similar. Remove the 6 pin-type retainers and detach the RH and LH air deflectors from the condenser. 14. Remove the 9 lower radiator splash shield pin-type retainers and position the shield aside. 15. Release the clamps and disconnect the 2 transmission cooler lines from the transmission cooler. 16. Detach the transmission cooler line pin-type retainer from the condenser core bracket. 17. NOTE: - The cooling module must be positioned rearward to raise and detach the 4 condenser mounts from the cooling module. - The condenser must be removed from below the vehicle. Detach and remove the condenser core and transmission cooler as an assembly. 1. Position the cooling module rearward enough to allow the condenser to be lifted upward. 2. Depress the retaining tabs on the 2 lower condenser mounting brackets and detach the 4 condenser mounting brackets from the cooling module 3. Position the top of the condenser forward to detach the top lip of the condenser bracket from the cooling module and remove the condenser core and bracket. 18. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 19. Fill the power steering fluid level. 20. Fill the transmission fluid level. 21. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Rear View 151-19 (Center Console - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Rear > Page 8172 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 orientation. 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Control Assembly: Connector Views C297 C3198 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Climate Control Control Assembly: Description and Operation Auxiliary Climate Control CONTROL ASSEMBLY The auxiliary climate control system has dual controls for the front and rear passengers consisting of temperature/mode and blower speed. The front auxiliary A/C control functionality is integrated into the main instrument panel mounted climate control assembly. The rear auxiliary A/C control is mounted in the rear finish panel of the front floor console. Temperature and airflow mode are combined into a single setting. When the temperature is set to full cool the airflow mode will be automatically set to discharge from the headliner registers. When the temperature is set to full warm, the airflow mode will be set to discharge from the floor register. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Climate Control > Page 8195 Control Assembly: Description and Operation Control Components CONTROL COMPONENTS Two climate control systems are available: - Electronic manual temperature control (EMTC) (Expedition only) - Dual-zone electronic automatic temperature control (EATC) Refer to the appropriate heading below for information concerning each system. Manual Climate Control The manual climate control components are used to select the following: Air inlet source (outside or recirculated) - Blower motor speed - Discharge air temperature (temperature blend) - Discharge air location (DEFROST, PANEL, FLOOR) - A/C compressor operation Control System Inputs - Electronic Manual Temperature Control Climate Control Assembly (EMTC Module) The climate control assembly integrates the temperature control, airflow mode selection, A/C request button, recirculated air request button and rear defog switch into a single unit. The temperature control setting determines air temperature. Movement of the temperature control from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the climate control assembly and cannot be installed separately. The airflow mode setting determines discharge air location. Movement of the mode selector causes a corresponding movement of the airflow mode door actuators. The mode selector is an integral part of the climate control assembly and cannot be installed separately. The A/C request button determines A/C compressor operation, except when the mode selector is in the OFF, MAX or DEFROST mode. The A/C request button is an integral part of the climate control assembly and cannot be installed separately. The recirculated air request button determines air inlet source, except when the airflow mode selector is in the OFF, MAX or DEFROST mode. The recirculated air request button is an integral part of the climate control assembly and cannot be installed separately. The rear defog button signals activation of the heated backlight and heated mirrors. The rear defog button is an integral part of the manual climate control assembly and cannot be installed separately. The EMTC module is not equipped with self-test capabilities. Control System Outputs - Electronic Manual Temperature Control Temperature Blend Door Actuator The temperature blend door actuator moves the temperature blend door on command from the EMTC module. The temperature blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a wiper which is driven along the variable resistor by the actuator shaft. The signal returned to the EMTC module from the wiper indicates the position of the temperature blend door. The EMTC module drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EMTC module wiper voltage value. The temperature blend door actuator is located on the heater core and evaporator core housing. Mode Door Actuators Electric mode door actuators are used to position the 3 airflow mode doors on command from the EMTC module. The 2 mode door actuators each contain a reversible electric motor. The DEFROST/PANEL/FLOOR door actuator contains a potentiometer to allow the EMTC module to monitor the position of the airflow mode doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a wiper which is driven along the variable resistor by the actuator shaft. The signal returned to the EMTC module from the wiper indicates the position of the airflow mode door. The air inlet mode door actuator is driven to the full RECIRC or full FRESH air inlet position, and does not require a potentiometer circuit to monitor its position. Dual-Zone Electronic Automatic Temperature Control The dual-zone EATC module analyzes input from the following major sources: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Climate Control > Page 8196 - Temperature, mode and blower selection (made by the vehicle occupants) - In-vehicle temperature - In-vehicle humidity (Navigator only) - Ambient temperature - Evaporator discharge air temperature - Sunload - Vehicle speed - Engine coolant temperature Using these inputs, the dual-zone EATC module determines the correct conditions for the following outputs: A/C compressor operation - Blower speed - LH side temperature blend door position - RH side temperature blend door position - Airflow mode door positions Control System Inputs - Dual-Zone EATC EATC Module (Climate Control Assembly) The EATC module provides an interface for the vehicle occupants to control the climate control system, or automatically controls the climate control system in the AUTO mode. The EATC module has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs). An on-board diagnostic (OBD) feature is incorporated to supply the technician with DTCs. These DTCs help direct the technician to the inoperative component. Steering Wheel Audio/Climate Control Switch The steering wheel audio/climate control switch allows the driver to adjust the passenger compartment temperature setting and manually override the blower motor speed setting. For removal and installation of the steering wheel audio/climate control switch, refer to Radio, Stereo, and Compact Disc. Ambient Air Temperature Sensor The ambient air temperature sensor contains a thermistor, which measures the temperature of outside air as a resistance and sends that reading to the dual-zone EATC module. In-Vehicle Temperature/Humidity Sensor - Navigator The in-vehicle temperature sensor contains 2 thermistors, which separately measure the in-vehicle air temperature and humidity and send those readings to the EATC module. An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature and humidity sensor. The aspirator hose uses airflow from the heater core and evaporator core housing air stream to create a venturi-type suction to draw in-vehicle air through the in-vehicle temperature sensor and across the thermistors. In-Vehicle Temperature Sensor - Expedition The in-vehicle temperature sensor contains a thermistor, which measures the in-vehicle air temperature and sends that reading to the EATC module. An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. The aspirator hose uses airflow through the heater core and evaporator core housing to create a venturi-type suction to draw in-vehicle air through the in-vehicle temperature sensor and across the thermistor. Dual-Zone Solar Amplifier (Sunload Sensor) The solar amplifier is a dual-zone type that supplies separate information to the dual-zone EATC module indicating LH side and RH side sunload. For information on the location and service of the solar amplifier, refer to Lighting and Horns. Control System Outputs - EATC Blower Motor Speed Control The blower motor speed control controls the blower motor speed by converting low power signals from the EATC module to a high current, variable ground feed for the blower motor. A delay function is used to provide a gradual increase or decrease in blower motor speed under all conditions. The blower motor speed control is located on the heater core and evaporator core housing near the blower motor. Temperature Blend Door Actuators The dual-zone EATC system uses 2 temperature blend door actuators to control 2 separate temperature blend doors. The temperature blend doors independently vary the LH side and RH side temperature settings, as desired. The temperature blend door actuators each contain a reversible electric motor and a potentiometer. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a wiper which is driven along the variable resistor by the actuator shaft. The signal returned to the EATC module from the wiper indicates the position of the temperature blend door. The EATC module drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EATC module wiper voltage value. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Climate Control > Page 8197 Mode Door Actuators Electric mode door actuators are used to position the 3 airflow mode doors on command from the EATC module. The 2 mode door actuators each contain a reversible electric motor. The DEFROST/PANEL/FLOOR door actuator contains a potentiometer to allow the EATC module to monitor the position of the airflow mode doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a wiper, which is driven along the variable resistor by the actuator shaft. The signal returned to the EATC module from the wiper indicates the position of the airflow mode door. The air inlet mode door actuator is driven to the full RECIRC or full FRESH air inlet position, and does not require a potentiometer circuit to monitor its position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Climate Control > Page 8198 Control Assembly: Description and Operation Heating and Ventilation HEATING AND VENTILATION The heating and ventilation system has the following features: - Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle. - Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level. - Cooling or heating can be adjusted to maintain the desired temperature. - Uses a reheat method to provide conditioned air to the passenger compartment. - All airflow from the blower motor passes through the A/C evaporator core. - Temperature blending is controlled by the temperature blend door(s), which regulate(s) the amount of air that flows through and around the heater core, where it is then mixed and distributed. Blower Motor The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing and the plenum chamber where it is mixed and distributed. Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum. Heater Core and Evaporator Core Housing The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). After passing through the heater core, the airflow is distributed to plenum chamber where it is distributed to the selected vehicle outlets. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly Control Assembly: Service and Repair Climate Control Assembly CLIMATE CONTROL ASSEMBLY Removal and Installation NOTE: Navigator shown, expedition similar. 1. Remove the center instrument panel 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 8201 Control Assembly: Service and Repair Auxiliary Climate Control Assembly AUXILIARY CLIMATE CONTROL ASSEMBLY Removal and Installation 1. Remove the floor console upper finish panel. 2. Remove the 2 floor console rear finish panel screws. 3. Disengage the 6 clips and remove the floor console rear finish panel. - Disconnect the 3 floor console harness electrical connectors. 4. Remove the 4 auxiliary climate control assembly screws. 5. Remove the auxiliary climate control assembly. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module > Page 8206 View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module C228A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8209 C228B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8210 Control Module HVAC: Diagrams Manual Climate Control Module C2357A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8211 C2357B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8212 C2357C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair Coupler HVAC: Service and Repair SPRING LOCK COUPLING Special Tool(s) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 8216 1. Fabricate a cleaning tool from a 1/8-in 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 PAG 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 8217 9. Clean the O-ring seal grooves with a 300 mm (12 in) 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 8218 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 08-9-8 > May > 08 > A/C - Whistle Noise When Changing Temperature Setting Evaporator Core: Customer Interest A/C - Whistle Noise When Changing Temperature Setting TSB 08-9-8 05/12/08 WHISTLE NOISE FROM THE HEATER/AIR CONDITIONING WHILE CHANGING TEMPERATURE SETTING - BUILT ON OR BEFORE 12/4/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 12/4/2007 may exhibit a whistle noise from the heater/air conditioning while changing temperature setting. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Confirm customer symptom by cycling the temperature door as follows: Manual System: 1. Set blower motor speed to number 2. 2. Set mode to PNL/FLR mode (most noticeable). Whistle may be audible in Vent or DEF/FLR but to a lesser extent. 3. Set the temperature knob all the way to full hot. 4. Start backing off full hot incrementally while listening for whistles. Whistle should be audible when the knob position is roughly between 5/8 and 3/4 position. Dual Air Temperature Control (DATC) System: 1. Manually set the blower motor speed to medium or medium high. 2. Manually set mode to PNL/FLR (most noticeable). May be audible in Vent and DEF/FLR. 3. Set the temperature set point to highest temperature 90 °F (32 °C). 4. Start reducing the temperature set point incrementally while listening for whistles. Since the blend door position is dictated by several inputs like in-car temp sensor, ambient temp sensor, and sun load sensor. The whistle can be anywhere in the range except full cold. If the whistle noise is present during the conditions above, replace the evaporator assembly. If the noise is not present during these conditions, refer to workshop manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 08-9-8 > May > 08 > A/C - Whistle Noise When Changing Temperature Setting > Page 8227 080908A 2007-2008 Expedition, 4.6 Hrs. Navigator Built Before 12/04/07: Replace The Evaporator Assembly, Includes Time To Evacuate And Charge System, Remove And Install Console, Instrument Panel, Steering Column (Do Not Use With 19700A, 19700A15, 19680A, 04320A, 04320B, 3514A, 04536A, 04536B, 18476A) DEALER CODING CONDITION BASIC PART NO. CODE 19B555 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 08-9-8 > May > 08 > A/C - Whistle Noise When Changing Temperature Setting Evaporator Core: All Technical Service Bulletins A/C - Whistle Noise When Changing Temperature Setting TSB 08-9-8 05/12/08 WHISTLE NOISE FROM THE HEATER/AIR CONDITIONING WHILE CHANGING TEMPERATURE SETTING - BUILT ON OR BEFORE 12/4/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 12/4/2007 may exhibit a whistle noise from the heater/air conditioning while changing temperature setting. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Confirm customer symptom by cycling the temperature door as follows: Manual System: 1. Set blower motor speed to number 2. 2. Set mode to PNL/FLR mode (most noticeable). Whistle may be audible in Vent or DEF/FLR but to a lesser extent. 3. Set the temperature knob all the way to full hot. 4. Start backing off full hot incrementally while listening for whistles. Whistle should be audible when the knob position is roughly between 5/8 and 3/4 position. Dual Air Temperature Control (DATC) System: 1. Manually set the blower motor speed to medium or medium high. 2. Manually set mode to PNL/FLR (most noticeable). May be audible in Vent and DEF/FLR. 3. Set the temperature set point to highest temperature 90 °F (32 °C). 4. Start reducing the temperature set point incrementally while listening for whistles. Since the blend door position is dictated by several inputs like in-car temp sensor, ambient temp sensor, and sun load sensor. The whistle can be anywhere in the range except full cold. If the whistle noise is present during the conditions above, replace the evaporator assembly. If the noise is not present during these conditions, refer to workshop manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 08-9-8 > May > 08 > A/C - Whistle Noise When Changing Temperature Setting > Page 8233 080908A 2007-2008 Expedition, 4.6 Hrs. Navigator Built Before 12/04/07: Replace The Evaporator Assembly, Includes Time To Evacuate And Charge System, Remove And Install Console, Instrument Panel, Steering Column (Do Not Use With 19700A, 19700A15, 19680A, 04320A, 04320B, 3514A, 04536A, 04536B, 18476A) DEALER CODING CONDITION BASIC PART NO. CODE 19B555 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Climate Control Evaporator Core: Description and Operation Climate Control EVAPORATOR CORE NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. Refer to Heating and Air Conditioning. - Installation of a new receiver/drier cartridge 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 cartridge. The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube, continues over to the remaining plate/fin sections and then moves out of the evaporator core through the evaporator core outlet tube. Air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Climate Control > Page 8236 Evaporator Core: Description and Operation Auxiliary Climate Control EVAPORATOR CORE NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. Refer to Heating and Air Conditioning. - Installation of a new receiver/drier cartridge 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 cartridge. The evaporator core is an aluminum plate/fin type and is located in the auxiliary climate control housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and then moves out of the evaporator core through the evaporator core outlet tube. When the A/C compressor is operating, air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 cartridge 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 cartridge. - A new evaporator core seal is supplied as a kit with the evaporator core service part. Failure to install this seal, or failure to install it correctly, will result in air bypassing the evaporator core and loss of cooling efficiency. 1. Remove the plenum chamber. 2. Remove 2 heater core quick disconnect fitting clips and the dash panel seal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8239 3. Detach the wire harness from the upper half of the heater core and evaporator core housing. 4. Remove the 6 air inlet duct screws and the air inlet duct. 5. Remove the 15 heater core and evaporator core housing screws. 6. Separate the 2 halves of the heater core and evaporator core housing. 7. Remove the evaporator core. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8240 Evaporator Core: Service and Repair Auxiliary Evaporator Core AUXILIARY EVAPORATOR CORE Removal and Installation NOTE: - The auxiliary evaporator core is not available as a separate component for Expedition EL or Navigator L vehicles and is serviced only as an assembly with the auxiliary heater core and evaporator core housing. The auxiliary evaporator core is serviced as an individual component for Expedition and Navigator vehicles. - 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 cartridge 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 cartridge. All vehicles 1. Remove the auxiliary heater core and evaporator core housing. Expedition EL 2. Transfer the components from the old heater core and evaporator core housing to the new heater core and evaporator core housing as needed. 3. Install the auxiliary heater core and evaporator core housing. Expedition or Navigator only 4. Remove the thermostatic expansion valve (TXV) fitting bolt and disconnect the fitting. - Discard the O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8241 5. Remove the 12 evaporator/heater core access cover screws. 6. Remove the evaporator/heater core access cover. - Disconnect the evaporator drain tube. 7. Remove the evaporator core. 8. To install, reverse the removal procedure. - Install new O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8245 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8246 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Discharge Air Temperature Sensor EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR The evaporator discharge air temperature sensor communicates the evaporator discharge air temperature to the electronic manual temperature control (EMTC) module (if equipped) or electronic automatic temperature control (EATC) module (if equipped). The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing in the air-stream leaving the evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor > Page 8249 Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Evaporator Temperature (ACET) Sensor 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 changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 8250 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Expansion Valve: Customer Interest A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8259 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8260 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8261 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Expansion Valve: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8266 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8267 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8268 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Expansion Valve: All Technical Service Bulletins A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8274 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8275 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8276 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Expansion Valve: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8281 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8282 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8283 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Climate Control Expansion Valve: Description and Operation Climate Control THERMOSTATIC EXPANSION VALVE The thermostatic expansion valve (TXV) is located between the evaporator core lines and the thermostatic expansion valve manifold and tube assembly at the RH rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system, and separates the low-pressure and high-pressure sides of the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Climate Control > Page 8286 Expansion Valve: Description and Operation Auxiliary Climate Control THERMOSTATIC EXPANSION VALVE (TXV) The TXV restricts the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the auxiliary refrigerant system. Refrigerant entering and exiting the auxiliary evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 cartridge 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 cartridge. All vehicles 1. Recover the refrigerant. Vehicles with auxiliary A/C 2. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the gasket seal and O-ring seal. - To install, tighten to 15 Nm (11 lb-ft). All vehicles 3. Disconnect the evaporator inlet and outlet fittings. - Discard the O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8289 4. Detach the thermostatic expansion valve (TXV) manifold and tube assembly from the 2 TXV manifold and tube brackets. 5. Remove the tie-strap from the TXV insulator. 6. Remove the TXV fitting bolt. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 bolts and the TXV. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 9. Evacuate, leak test and charge the refrigerant system. Thermostatic Expansion Valve Manifold and Tube Assembly THERMOSTATIC EXPANSION VALVE MANIFOLD AND TUBE ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8290 Removal and Installation NOTE: Installation of a new receiver/drier cartridge 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 cartridge. 1. Recover the refrigerant. 2. Remove the RH headlamp assembly. 3. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Disconnect the evaporator core inlet and outlet fittings. - Discard the O-ring seals. 5. Detach the thermostatic expansion valve (TXV) manifold and tube assembly from the 2 TXV manifold and tube brackets. 6. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 7. Remove the TXV manifold and tube suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 8. Remove the TXV manifold and tube assembly. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8291 - 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8292 Expansion Valve: Service and Repair Auxiliary Climate Control Thermostatic Expansion Valve THERMOSTATIC EXPANSION VALVE Removal and Installation 1. Recover the refrigerant. 2. Remove the RH quarter trim panel. 3. Remove the thermostatic expansion valve (TXV) fitting bolt and disconnect the fitting. - Discard the O-ring seals. 4. Remove the 2 TXV bolts. 5. Remove the TXV. - Discard the O-ring seals. 6. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 7. Evacuate, leak test and charge the refrigerant system. Thermostatic Expansion Valve - Expedition EL, Navigator L THERMOSTATIC EXPANSION VALVE - EXPEDITION EL, NAVIGATOR L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8293 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the auxiliary evaporator outlet and inlet line rear fitting nut. - Discard the gasket seals. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the 2 thermostatic expansion valve (TXV) bolts and the TXV. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. - Install new O-ring seals and gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8302 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8303 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8309 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8310 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8311 Heater Core: Description and Operation HEATER CORE The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the auxiliary climate control housing. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 8 plenum chamber screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8314 3. Release the plenum chamber clip and position the plenum chamber aside. 4. Remove 2 heater core fitting clips and the dash panel seal. 5. Remove the heater core tube bracket screw and the heater core tube bracket. 6. Remove the heater core bracket screw and the heater core bracket. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8315 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. 1. Remove the auxiliary heater core and evaporator core housing. 2. Release the clip and open the floorpan bracket. 3. Remove the heater core tube bracket screw and the heater core tube bracket. 4. Remove the 12 evaporator/heater core access cover screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8316 5. Remove the evaporator/heater core access cover. 6. Remove the heater core. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8317 Heater Core: Service and Repair Auxiliary Heater Core - Expedition EL, Navigator L AUXILIARY HEATER CORE - EXPEDITION EL, NAVIGATOR L Removal and Installation NOTE: - If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. - It is not necessary to install the new heater core tubes contained in the heater core service kit unless there is evidence of damage to the heater core tubes. New O-ring seals must be installed any time the heater core tubes are detached from the heater core. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the RH quarter trim panel. 4. Position a suitable drain pan and disconnect the 2 auxiliary heater outlet and inlet line quick disconnect fittings at the floorpan connections to allow any residual coolant to drain from the auxiliary heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8318 5. Remove the heater core door screw. 6. Remove the 2 auxiliary heater core tube fitting clips. 7. Disconnect the 2 auxiliary heater core tubes. 1 Position the auxiliary heater core partially out of the housing. 2 Disconnect the auxiliary heater core inlet tube. 3 Disconnect the auxiliary heater core outlet tube. Discard the O-ring seals. 8. Remove the auxiliary heater core. 9. NOTE: - Use only the O-ring seals contained in the auxiliary heater core service kit. - Verify that the heater core tube fittings are completely seated in the heater core before installing the heater core tube fitting clips. To install, reverse the removal procedure. 10. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 8327 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 (2007)) 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 8328 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 (2007)) 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 (2007)) 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 8334 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 (2007)) 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 8335 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures Heater Hose: Procedures HEATER HOSE COUPLING Special Tool(s) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures > Page 8338 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 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures > Page 8339 Heater Hose: Removal and Replacement AUXILIARY HEATER OUTLET AND INLET LINE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures > Page 8340 Part 2 Removal NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. - The following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the RH fender splash shield. 5. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s). 6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition EL or Navigator L only 8. Remove the RH rear wheel and tire assembly. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures > Page 8341 9. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s). 10. Remove the muffler. 11. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 12. Remove the 3 muffler heat shield bolts and the muffler heat shield. 13. Remove the 2 exhaust hanger bolts and the exhaust hanger. 14. Remove the RH catalyst monitoring sensor. 15. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 16. Remove the 3 remaining auxiliary line bracket nuts and the line brackets. 17. 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). 18. Remove the auxiliary heater line(s) in 3 separate pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings. All vehicles 2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings. 3. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). 4. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 5. Tighten the middle auxiliary heater line fittings. 6. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 7. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts. 8. Install the RH catalyst monitoring sensor. 9. Install the exhaust hanger and the 2 exhaust hanger bolts. 10. Install the muffler heat shield and the 3 muffler heat shield bolts. 11. Install the muffler. 12. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 13. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 14. Install the front auxiliary line bracket and the front auxiliary line bracket and nut. - Tighten to 5 Nm (44 lb-in). 15. Install the RH front fender splash shield. 16. Install the RH front wheel. Expedition EL or Navigator L only 17. Install the RH rear wheel and tire assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Procedures > Page 8342 All vehicles 18. Install the spare tire. 19. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation A/C COMPRESSOR PRESSURE RELIEF VALVE An A/C compressor pressure relief valve is incorporated in the compressor to prevent damage to the A/C compressor and other system components, and to avoid total refrigerant loss by relieving unusually high refrigerant system discharge pressure buildups. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Hose/Line HVAC: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8354 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8355 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8356 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Hose/Line HVAC: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8362 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8363 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8364 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 8365 Hose/Line HVAC: Description and Operation AUXILIARY A/C - HEATER LINES The auxiliary lines are secured to the underbody of the vehicle. Each auxiliary line is only available as a multiple-piece kit for ease of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8368 Part 2 Removal NOTE: - The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly for Expedition or Navigator vehicles. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. - The auxiliary evaporator inlet and outlet lines for Expedition EL or Navigator L vehicles are installed from the factory as a single one-piece assembly including both lines. The replacement part is supplied as a multiple-piece kit for ease of installation. - For Expedition or Navigator vehicles, the following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. For Expedition EL or Navigator L vehicles, both lines must be removed. - Installation of a new receiver/drier cartridge 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 cartridge. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the auxiliary evaporator outlet and inlet line front fitting nut(s) and disconnect the fitting(s). Discard the O-ring seals and gasket seals. 4. Remove the spare tire. 5. Remove the RH fender splash shield. 6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8369 7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition or Navigator only 8. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the auxiliary evaporator outlet and inlet line rear fittings. Discard the O-ring seals. Expedition EL or Navigator L only 9. Remove the RH rear wheel and tire assembly. 10. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. - Discard the gasket seals. All vehicles 11. Remove the muffler. 12. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 13. Remove the 3 muffler heat shield bolts and the heat shield. 14. Remove the 2 exhaust hanger bolts and the exhaust hanger. 15. Remove the RH catalyst monitoring sensor. 16. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 17. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary 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). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8370 19. NOTE: - Expedition EL shown. - For Expedition EL or Navigator L vehicles, the middle portion of the auxiliary evaporator outlet and inlet lines can be removed through the RH rear wheel well opening between the body and the frame. Remove the auxiliary evaporator line(s) in 3 separate pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary evaporator line(s) and connect the auxiliary evaporator outlet and inlet line rear fittings. - Install new O-ring seals. Expedition EL or Navigator L only 2. Install the rear portion of the auxiliary evaporator outlet and inlet line. 3. Connect the auxiliary evaporator outlet and inlet line rear fitting and install the nut. - Install new gasket seals. - Tighten to 12 Nm (9 lb-ft). All vehicles 4. Install the front portion of the auxiliary evaporator outlet and inlet line(s). 5. Connect the evaporator outlet and inlet line front fitting(s) and install the nut(s). - Install new O-ring seals and gasket seals. - Tighten to 15 Nm (11 lb-ft). 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 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8371 8. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar. 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 RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts. 11. Install the exhaust hanger and the 2 exhaust hanger bolts. 12. Install the muffler heat shield and the 3 muffler heat shield bolts. 13. Install the RH catalyst monitoring sensor. 14. Install the muffler. 15. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 16. Install the front auxiliary line bracket and the front auxiliary line bracket nut. - Tighten to 5 Nm (44 lb-in). 17. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 18. Install the RH front fender splash shield. 19. Install the RH front wheel. Expedition EL or Navigator L only 20. Install the RH rear wheel and tire assembly. All vehicles 21. Install the spare tire. 22. Lubricate the refrigerant system with the correct amount of clean PAG oil. 23. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8372 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation NOTE: Installation of a new receiver/drier cartridge 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 cartridge. 1. Recover the refrigerant. 2. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the condenser inlet jumper line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the compressor-to-condenser discharge line. 5. If removing the condenser inlet jumper line, remove the RH headlamp assembly. 6. If removing the condenser inlet jumper line, disconnect the A/C pressure transducer electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 8373 7. If removing the condenser inlet jumper line, remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (11 lb-ft). 8. Remove the condenser inlet jumper line. 9. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing HEATER CORE AND EVAPORATOR CORE HOUSING Removal and Installation NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8378 - 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 cartridge 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 cartridge. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. 4. Disconnect the 2 heater hose quick disconnect fittings at the heater core. 5. Remove the auxiliary evaporator outlet and inlet line fitting nuts and disconnect the fittings. - Discard the O-ring seals and gasket seals. - To install, tighten to 15 Nm (11 lb-ft). 6. Disconnect the evaporator outlet and inlet fittings. - Discard the O-ring seals. 7. Detach the thermostatic expansion valve (TXV) manifold and tube assembly from the line 2 brackets. 8. Detach the TXV manifold and tube assembly bracket from the heater core and evaporator core housing stud at the dash panel. 9. Remove the 3 heater core and evaporator core housing nuts. - To install, tighten to 7 Nm (62 lb-in). 10. Detach the 4 satellite radio antenna cable pin-type retainers from the heater core and evaporator core housing (if equipped). 11. Detach the 3 body harness electrical connectors from the bracket below the air inlet duct. 12. Remove the air inlet duct bracket nut. - To install, tighten to 7 Nm (62 lb-in). 13. Remove the plenum chamber nut. - To install, tighten to 7 Nm (62 lb-in). 14. Remove the 4 tunnel instrument panel bracket bolts and the tunnel instrument panel bracket. 15. Detach the rear footwell duct from the heater core and evaporator core housing. 16. Remove the plenum chamber nut. 17. Remove the heater core and evaporator core housing. 18. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 19. Fill the engine coolant level. 20. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8379 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 mode door actuator electrical connector and position the wire harness aside. 3. Remove the 8 plenum chamber screws. 4. Release the plenum chamber clip and remove 5. To install, reverse the removal procedure. the plenum chamber. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8380 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing AUXILIARY HEATER CORE AND EVAPORATOR CORE HOUSING Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8381 3. Drain the engine coolant. 4. NOTE: Allow any residual coolant to drain from the auxiliary heater core after disconnecting the auxiliary heater hose fittings. Position a suitable drain pan and disconnect the 2 auxiliary heater hose fittings at the floorpan connection. 5. Disconnect the 2 auxiliary evaporator line fittings at the floorpan connection. - Discard the O-ring seals. 6. Remove the 2 floorpan bracket bolts. 7. Remove the auxiliary headliner duct pin-type retainer and disconnect the duct. 8. Disconnect the auxiliary mode door actuator electrical connector. 9. Disconnect the auxiliary temperature blend door actuator electrical connector. 10. Disconnect the auxiliary blower motor resistor electrical connector. 11. Disconnect the auxiliary blower motor electrical connector and detach the wire harness from the housing. 12. Remove the 2 auxiliary heater core and evaporator core housing bolts. - To install, tighten to 8 Nm (71 lb-in). 13. Remove the auxiliary heater core and evaporator core housing. 14. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 15. Fill the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8382 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing - Expedition EL, Navigator L AUXILIARY HEATER CORE AND EVAPORATOR CORE HOUSING - EXPEDITION EL, NAVIGATOR L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 8383 2. Recover the refrigerant. 3. Drain the engine coolant. 4. Remove the RH rear quarter trim panel. 5. NOTE: Allow any residual coolant to drain from the auxiliary heater core after disconnecting the auxiliary heater core fittings. Position a suitable drain pan and disconnect the 2 auxiliary heater core quick disconnect fittings. 6. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 12 Nm (9 lb-ft). 7. Disconnect the auxiliary climate control harness electrical connector. 8. Remove the auxiliary airflow duct bolt. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 heater core and evaporator core housing bolts. - To install, tighten to 8 Nm (71 lb-in). 10. Remove the auxiliary heater core and evaporator core housing. 11. To install, reverse the removal procedure. - Install new gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Fill the engine coolant level. 13. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Diagrams C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Receiver Dryer: Customer Interest A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8395 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8396 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8397 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Receiver Dryer: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8402 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8403 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Customer Interest for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8404 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures Receiver Dryer: All Technical Service Bulletins A/C - Compressor Cuts Out in High Temperatures TSB 07-26-3 12/24/07 A/C COMPRESSOR - CUTS OUT HIGH AMBIENT TEMPERATURES/SEIZED - POOR A/C PERFORMANCE - BUILT BEFORE 11/1/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance. Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following. Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures. NOTE AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM. NOTE CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM. NOTE WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB. A/C SLOW TO COOL/NOT COOL ENOUGH 1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00. 2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding. 4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8410 5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below. When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8411 .33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C Flush And Purge - Without Rotunda Machine: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. 22 oz. - Front A/C 33 oz. - With Auxiliary A/C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-26-3 > Dec > 07 > A/C - Compressor Cuts Out in High Temperatures > Page 8412 NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES 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 MT072603 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Receiver Dryer: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8417 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8418 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Receiver Dryer: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8419 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Page 8420 Receiver Dryer: Description and Operation RECEIVER/DRIER NOTE: Installation of a new receiver/drier cartridge 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 cartridge. The receiver/drier is integral to the A/C condenser/power steering combo cooler. It stores high-pressure liquid after it leaves the condenser core. An A/C desiccant cartridge mounted inside the receiver/drier removes any retained moisture from the refrigerant. The receiver/drier cartridge is a separate component and can be removed and installed separately from the A/C condenser/power steering combo cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > Page 8421 Receiver Dryer: Service and Repair RECEIVER DRIER Removal and Installation NOTE: Installation of a new receiver/drier cartridge 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 cartridge. 1. Remove the condenser core. 2. Unscrew and remove the plastic receiver/drier cap. 3. Remove the receiver/drier plug. 1 Push the receiver/drier plug upwards and remove the snap ring. 2 Install the bolt included with the receiver/drier cartridge service kit in the center of the receiver drier plug and remove the plug. 4. Using a suitable tool, grasp the receiver/drier cartridge grab handle and remove the receiver/drier cartridge. 5. To install, reverse the removal procedure. - Lubricate the receiver/drier plug O-ring seals using residual refrigerant oil from inside the receiver/drier. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8426 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8427 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. 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. Refer to Heating and Air Conditioning. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Refrigerant Filter: Customer Interest A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8436 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8437 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8438 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Refrigerant Filter: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8444 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8445 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 8446 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8451 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL TYPE (R-134a Systems) PAG Refrigerant Compressor Oil Ford P/N ........................................................... .................................................................................................................................................. YN-12-D Ford Specification ................................................................................................................. ................................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8455 C1260 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer A/C PRESSURE TRANSDUCER The A/C pressure transducer communicates the compressor discharge pressure to the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates excessively high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8458 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch AIR CONDITIONING (A/C) CYCLING SWITCH The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8459 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8460 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor AIR CONDITIONING PRESSURE (ACP) TRANSDUCER SENSOR A/C Pressure Transducer Sensor Output Voltage Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8466 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8467 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8468 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8471 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8472 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8473 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8474 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8475 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8476 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8477 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8478 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8479 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8480 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8481 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8485 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 is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8486 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8487 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8488 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Automatic Temperature Control (EATC) Module > Page 8493 View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module C228A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8496 C228B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8497 Control Module HVAC: Diagrams Manual Climate Control Module C2357A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8498 C2357B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 8499 C2357C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8504 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8505 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector positions except OFF. The blower motor switch is mounted to the climate control assembly and can be separately installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 8509 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 8515 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor 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 3 lower steering column cover screws and the lower steering column cover. - Disconnect the electrical connector. 2. Remove the 4 steering column reinforcement bolts and position the steering column reinforcement aside. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the in-vehicle temperature and humidity sensor. 1 Detach the in-vehicle temperature and humidity sensor from the instrument panel finish panel. 2 Disconnect the aspirator hose. 3 Disconnect the in-vehicle temperature and humidity sensor electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature and Humidity Sensor > Page 8518 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View 151-46 (Climate Control System - Manual A/C) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8522 View 151-47 (Climate Control System - EATC) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 8523 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Discharge Air Temperature Sensor EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR The evaporator discharge air temperature sensor communicates the evaporator discharge air temperature to the electronic manual temperature control (EMTC) module (if equipped) or electronic automatic temperature control (EATC) module (if equipped). The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator discharge air temperature sensor is located on the heater core and evaporator core housing in the air-stream leaving the evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Discharge Air Temperature Sensor > Page 8526 Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Evaporator Temperature (ACET) Sensor 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 changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 8527 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8534 C1260 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer A/C PRESSURE TRANSDUCER The A/C pressure transducer communicates the compressor discharge pressure to the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates excessively high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8537 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch AIR CONDITIONING (A/C) CYCLING SWITCH The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8538 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer > Page 8539 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor AIR CONDITIONING PRESSURE (ACP) TRANSDUCER SENSOR A/C Pressure Transducer Sensor Output Voltage Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8543 Solar Sensor: Diagrams C286 C2360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SERVICE GAUGE PORT VALVES The high-pressure service gauge port valve is located on the high-pressure side of the TXV manifold and tube at the RH rear of the engine compartment. The low-pressure service gauge port valve is located on the low-pressure side of the TXV manifold and tube at the RH rear of the engine compartment. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A very small amount of leakage will always be detectable around the Schrader-type valve, with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively. - The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8550 Solar Sensor: Diagrams C286 C2360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative Wiring Harness HVAC: Customer Interest A/C - Climate Seat Function Inoperative TSB 08-23-11 11/24/08 INOPERATIVE OR NO COMMUNICATION WITH DUAL CLIMATE CONTROL SEAT MODULE (DCSM) FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 MKZ, MKX, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles may exhibit inoperative climate seat function with no communication to the DCSM due to a ground concern. ACTION Follow service procedure to correct concern. SERVICE PROCEDURE NOTE THIS PROCEDURE ONLY APPLIES IF DAMAGE HAS BEEN IDENTIFIED AT THE SPECIFIC CONNECTOR AND PIN. IF DAMAGE IS NOT VISIBLE AT THE SPECIFIC CONNECTOR AND PIN, THIS PROCEDURE DOES NOT APPLY AND CONTINUE WITH NORMAL DIAGNOSTICS IN THE APPROPRIATE WORKSHOP MANUAL. Refer to Workshop Manual (WSM), Section 501-10 to gain access to the DCSM connector. Seat removal may be required. Zephyr-MKZ: If Connector C3305A is damaged at Pin M GD139 (BK-YE), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. Expedition-Navigator: If Connector C3265A is damaged at Pin M GD138 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 8559 position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. MKX: If Connector C3036A is damaged at Pin M GD145 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. NOTE IF PIN M IS DAMAGED ON THE MODULE THE DCSM MAY NEED TO BE REPLACED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082311A 2007-2008 MKX: Replace 1.5 Hrs. Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2006 Zephyr, 2007-2008 1.4 Hrs. MKZ: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2007-2008 Expedition, 1.3 Hrs. Navigator: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311B 2006 Zephyr, 2007-2008 1.6 Hrs. MKX And MKZ: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 8560 12650D) 082311B 2007-2008 Expedition, 1.5 Hrs. Navigator: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 14S411 X1 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative Wiring Harness HVAC: All Technical Service Bulletins A/C - Climate Seat Function Inoperative TSB 08-23-11 11/24/08 INOPERATIVE OR NO COMMUNICATION WITH DUAL CLIMATE CONTROL SEAT MODULE (DCSM) FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 MKZ, MKX, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles may exhibit inoperative climate seat function with no communication to the DCSM due to a ground concern. ACTION Follow service procedure to correct concern. SERVICE PROCEDURE NOTE THIS PROCEDURE ONLY APPLIES IF DAMAGE HAS BEEN IDENTIFIED AT THE SPECIFIC CONNECTOR AND PIN. IF DAMAGE IS NOT VISIBLE AT THE SPECIFIC CONNECTOR AND PIN, THIS PROCEDURE DOES NOT APPLY AND CONTINUE WITH NORMAL DIAGNOSTICS IN THE APPROPRIATE WORKSHOP MANUAL. Refer to Workshop Manual (WSM), Section 501-10 to gain access to the DCSM connector. Seat removal may be required. Zephyr-MKZ: If Connector C3305A is damaged at Pin M GD139 (BK-YE), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. Expedition-Navigator: If Connector C3265A is damaged at Pin M GD138 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 8566 position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. MKX: If Connector C3036A is damaged at Pin M GD145 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. NOTE IF PIN M IS DAMAGED ON THE MODULE THE DCSM MAY NEED TO BE REPLACED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082311A 2007-2008 MKX: Replace 1.5 Hrs. Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2006 Zephyr, 2007-2008 1.4 Hrs. MKZ: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2007-2008 Expedition, 1.3 Hrs. Navigator: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311B 2006 Zephyr, 2007-2008 1.6 Hrs. MKX And MKZ: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 8567 12650D) 082311B 2007-2008 Expedition, 1.5 Hrs. Navigator: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 14S411 X1 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 8573 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 (2007)) 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 8574 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION 1. 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: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Carry out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8580 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8581 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8582 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8583 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8584 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8585 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8586 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8587 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8588 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8589 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8590 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8591 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8592 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module View 151-17 (Steering Wheel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 8597 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 8598 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 8599 View 151-12 (Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module Air Bag: Diagrams Driver Air Bag Module C216A C216B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8602 C256 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8603 C9006 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8604 C9007 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8605 Air Bag: Diagrams C216A C216B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8606 C256 C9006 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8607 C9007 C3226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 8608 C3227 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 8609 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 Vehicles are equipped with safety canopies for protection during side impacts or rollover. Vehicles 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 D-pillar frame. - is standard equipment. - cannot be interchanged from side to side. - is used in conjunction with side air bag module. Loops/Squib All deployable devices contain an initiating device called a squib. The squib is part of the deployment loop. Air bag/safety canopy modules can contain more than one squib, some vehicles may have up to 4 squibs in one air bag module. Squibs are often referred to as loops during the diagnostic process. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 trim cover pointed away from your body.This will reduce the risk of injury in the event of an accidental deployment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8612 - 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. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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. Make sure the road wheels are in the straight-ahead position. 2. Center the tilt steering column. 3. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). 4. Depower the system. Vehicles with manual tilt wheel 5. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8613 6. Remove the screw and steering column manual tilt lever. All vehicles 7. Remove the 3 steering column lower shroud screws. 8. Release the clips and remove the steering column upper shroud. 9. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 10. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 11. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 12. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12'o clock position). Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8614 All vehicles 1. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. 2. Position the driver air bag module to the steering wheel lining up the locator pins. 3. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 4. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch. 5. Install the steering column upper shroud. 6. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 7. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 8. Install the lower steering column opening cover and the 3 screws. All vehicles 9. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8615 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE Expedition Passenger Air Bag Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8616 Navigator Passenger Air Bag 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8617 - Air bag modules with discolored or damaged deployment doors must be replaced, not repainted. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 the glove compartment door. - If equipped, disconnect the glove compartment door dampener. 3. Disconnect the passenger air bag module electrical connector. Expedition vehicles 4. Remove the 4 passenger air bag module deployment door screws. All vehicles 5. Remove the 4 passenger air bag module bolts. - To install, tighten to 9 Nm (80 lb-in). 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 bottom of the passenger air bag module deployment door releasing the bottom clips.Then remove the passenger air bag module from the instrument panel. 7. NOTE: During passenger air bag module installation, make sure all the deployment door clips are fully seated into the instrument panel. To install, reverse the removal procedure. 8. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8618 Air Bag: Service and Repair Safety Canopy Module SAFETY CANOPY MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8619 Part 2 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 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, C, and D-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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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. - The passenger side safety canopy module is shown, driver side similar. All vehicles 1. Depower the system. 2. Remove the headliner. Vehicles with a moon roof Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8620 3. Disconnect the moon roof rear drain hose and release the drain hose retainer from the coat hook bracket. All vehicles 4. Disconnect the safety canopy module electrical connector. 5. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheetmetal for installation. Remove the front tether cord bolt and bracket from the A-pillar. 6. Remove the 2 front tether cord pin-type retainers from the A-pillar sheetmetal. 7. Remove the 2 safety canopy module front bolts and the one B-pillar bracket bolt. Expedition/Navigator vehicles 8. Detach the safety canopy module rear tether cord routing clip pin-type retainer from the sheetmetal. 9. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheetmetal for installation. Remove the bolt and the safety canopy module rear tether cord anchor bracket from the D-pillar. Expedition EL/Navigator L vehicles 10. Detach the 3 safety canopy module rear tether cord routing clip pin-type retainers from the sheetmetal. 11. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheetmetal for installation. Remove the bolt and the safety canopy module rear tether cord anchor bracket from the D-pillar. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8621 All vehicles 12. Remove the C-pillar safety canopy module bolt. 13. Remove the 2 safety canopy module rear bolts and the one roof bracket bolt. 14. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook from the sheetmetal. 15. Move the safety canopy module forward to release the rear bracket hook from the sheetmetal and remove the safety canopy module. 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. Position safety canopy module by moving it rearward installing the rear bracket hook in the sheetmetal. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8622 2. Install the safety canopy module B-pillar bracket hook in the sheetmetal. 3. Install the safety canopy module B-pillar bracket bolt. - Tighten to 9 Nm (80 lb-in). 4. Install the safety canopy module roof bracket bolt. - Tighten to 9 Nm (80 lb-in). 5. Install the 2 safety canopy module rear bolts. - Tighten to 9 Nm (80 lb-in). 6. Install the C-pillar safety canopy module bolt. - Tighten to 9 Nm (80 lb-in). Expedition EL/Navigator L vehicles 7. Install the safety canopy module rear tether cord anchor bracket and bolt to the D-pillar. - Tighten to 9 Nm (80 lb-in). 8. Attach the 3 safety canopy module rear tether cord routing clip pin-type retainers to the sheetmetal. Expedition/Navigator vehicles 9. Install the safety canopy module rear tether cord anchor bracket and bolt to the D-pillar. - Tighten to 9 Nm (80 lb-in). 10. Attach the safety canopy module rear tether cord routing clip pin-type retainer to the sheetmetal. All vehicles 11. Install the 2 safety canopy module front bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 8623 - Tighten to 9 Nm (80 lb-in). 12. Install the 2 front tether cord pin-type retainers to the A-pillar sheetmetal. 13. Install the front tether cord bracket and bolt to the A-pillar. - Tighten to 6 Nm (53 lb-in). 14. Connect the safety canopy module electrical connector. Vehicles with a moonroof 15. Connect the moon roof rear drain hose and attach the drain hose retainer to the coat hook bracket. All vehicles 16. Install the headliner. 17. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8627 Air Bag Control Module: Diagrams C310A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8628 C310B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8629 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, a new RCM must be installed whether or not the air bags have deployed.In addition, make sure the area of the RCM mounting is restored to its original condition.Failure to follow these instructions may increase the risk of personal injury or death in a crash. CAUTION: Prior to removal of the RCM module, it is necessary to upload module configuration information to the scan tool.This information needs to be downloaded into the new RCM module once installed.Refer to Information Bus (Module Communications Network). NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON.The warning indicator will remain on until PCM configuration is restored.Clear RCM DTCs. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed.RCMs are not interchangeable between vehicles or vehicle lines.If an incorrect RCM is installed, erroneous DTCs and incorrect diagnosis 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 warning indicator if a fault is detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). 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 request illumination of the air bag warning indicator located in the instrument cluster. When the ignition switch is cycled (turned OFF and then ON), the air bag warning indicator will prove out by lighting for 6 seconds and then turn off.If a SRS fault exists, the air bag warning indicator will illuminate and remain illuminated for the rest of the key cycle.The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool.If the RCM requests illumination of the air bag warning indicator and the air bag warning indicator does not function, the instrument cluster module will automatically 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 warning indicator require repair. The RCM includes a backup power supply.This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is lost or damaged during impact.The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. A new RCM installed in a vehicle will flash lamp fault code (LFC) 54 until programmable module installation (PMI) has been carried out on the RCM.If a LFC is present after completing PMI, a fault is present in the SRS and on-demand DTCs must be retrieved and diagnosed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8630 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 RCM orientation is critical for proper air bag SRS operation. If a vehicle equipped with an SRS system has been involved in a Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8631 collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed 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. - When installing a new RCM, it is necessary to carry out programmable module installation (PMI). NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new 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 1. If installing a new restraints control module (RCM), carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the system. Vehicles with a center console 3. Remove the center console. Vehicles with bucket seats and no center console 4. Remove the 3 RCM push-nut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8632 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Install the RCM and 3 bolts. Tighten to 11 Nm (8 lb-ft). 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 (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8633 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats and no center console 6. Install the 3 RCM push-nut retainers and the RCM cover. Vehicles with a center console 7. Install the center console. All vehicles 8. Repower the SRS. Do not prove out the SRS at this time. 9. When installing a new RCM, carry out the steps necessary to complete programmable module installation (PMI). 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash. The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8634 exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous memory diagnostic trouble codes (DTCs) from the RCM. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8638 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 (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8639 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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. 1. Center the tilt steering column. 2. Depower the system. 3. Remove the driver air bag module. 4. NOTE: Make sure the road wheels are in the straight-ahead position. Remove the steering wheel. 5. Disconnect the clockspring electrical connector. 6. Remove the 2 screws and remove the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8640 Installation All vehicles 1. Install the clockspring and the 2 screws. 2. Connect the clockspring electrical connector. Vehicles installing a new clockspring 3. Install the steering wheel. - After the steering wheel installation, remove the clockspring sealing key. Vehicle repairs reusing the same clockspring 4. 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. If the vehicle's clockspring has rotated out of center, follow these steps to center 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 and for a slight resistance. Stop turning at this Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 8641 point. 3 Turn the clockspring clockwise (approximately 2 turns) until the clockspring rotor wiring and connector are in the 12 o'clock position. clockspring is now centered. Do not allow the rotor to turn from this position. 5. 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. All vehicles 6. Install the driver air bag module. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8646 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8647 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8648 Impact Sensor: Locations Safety Canopy Sensor, Driver 2 View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8649 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8650 Impact Sensor: Locations Safety Canopy Sensor, Passenger 2 View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8651 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8654 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8655 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8656 C3314 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8657 C3315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 8658 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, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - 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. Install a new and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. For these vehicles, the SRS uses 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel, the second row sensors are located on each C-pillar. The side impact sensors are not interchangeable between the first and second row. Mounting orientation is critical for correct operation of all impact sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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. - The front impact severity sensor is located on the bottom of the lower radiator support. 1. Depower the system. 2. Disconnect the front impact severity sensor electrical connector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8661 - Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of the locator tab on the front impact severity sensor for installation. Remove the bolt and front impact severity sensor. To install, tighten to 11 Nm (8 lb-ft). 4. To install, reverse the removal procedure. 5. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8662 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8663 procedure again. - RH side shown, LH similar. 1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. NOTE: Make sure the second row safety belt retractor belt webbing is not twisted prior to installation. Remove the bolt and second row safety belt retractor anchor. To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips to access the C-pillar side impact sensor. 6. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the side impact sensor locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the side impact sensor bolt. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the removal procedure. 9. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8664 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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: - Avoid applying corrosion protection to any safety, mechanical and electrical parts, electric motors, speakers, door locks and drain holes. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 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 (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8665 3. Separate the weathershield from the door 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 screws is critical for correct system operation. 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 tab for installation. Remove the 2 screws and side impact sensor. To install, tighten to 3 Nm (27 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Raise the driver seat and then position it to the rear of the track. 2. Depower the system. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the seat position sensor electrical connector and remove the seat position sensor and bracket. 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation Side Air Bag: Description and Operation SIDE AIR BAG MODULE NOTE: - References to side air bag modules refer to the seat-mounted, not to the steering wheel or instrument panel mounted air bag components of the SRS. - When servicing a seat equipped with a side air bag module, refer Seats. A side air bag module provides protection of the thorax area (between the neck and abdomen) of the body, working in conjunction with the head protection provided by a safety canopy module. The side air bag module: - will deploy upon receiving a flow of current from the RCM, initiated by the side impact sensor and internal RCM circuitry. - is installed as an assembly. - is mounted in the driver or passenger seat backrest. - is used in conjunction with a safety canopy module. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 8672 Side Air Bag: Service and Repair SIDE AIR BAG MODULE 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 side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover, side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 8673 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. 1. Position the affected seat and backrest fully up and forward. 2. Depower the system. 3. Release the seat backrest cover lower rear J-clip, then unzip the 2 side zippers. 4. NOTE: Note the position of the side air bag module locator pin to the seat backrest frame for installation. Remove the 2 side air bag module nuts. To install, tighten to 10 Nm (89 lb-in). 5. NOTE: Note the position of the side air bag module locator pin and mounting studs in the seat backrest trim cover deployment chute for installation. Position the seat backrest foam aside and remove the side air bag module from the seat backrest frame. Then slide the side air bag module out of the seat backrest trim cover deployment chute. 6. Disconnect the electrical connector and remove the side air bag module. 7. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the side air bag module deployment chute, a new seat back trim cover and side air bag module deployment chute must be installed as a unit. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the side air bag module cover has separated or the side air bag module material has been exposed, install a new side air bag module. Do not attempt to repair the side air bag module. Failure to do so may result in personal injury in the event of an air bag deployment. To install, reverse the removal procedure. 8. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation SECONDARY AIR BAG WARNING (CHIME) The secondary air bag warning chime, is an audible chime controlled by the instrument cluster module (ICM). If the ICM has detected a fault with the air bag warning indicator a diagnostic trouble code (DTC) will be stored in memory of the ICM. Upon receiving the message from the restraints control module (RCM) that a SRS fault has been detected, the ICM will sound the secondary air bag warning chime in a pattern of 5 sets of 5 beeps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-22 (RH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8681 Air Bag Control Module: Diagrams C310A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8682 C310B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8683 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, a new RCM must be installed whether or not the air bags have deployed.In addition, make sure the area of the RCM mounting is restored to its original condition.Failure to follow these instructions may increase the risk of personal injury or death in a crash. CAUTION: Prior to removal of the RCM module, it is necessary to upload module configuration information to the scan tool.This information needs to be downloaded into the new RCM module once installed.Refer to Information Bus (Module Communications Network). NOTE: - When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch is ON.The warning indicator will remain on until PCM configuration is restored.Clear RCM DTCs. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed.RCMs are not interchangeable between vehicles or vehicle lines.If an incorrect RCM is installed, erroneous DTCs and incorrect diagnosis 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 warning indicator if a fault is detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). 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 request illumination of the air bag warning indicator located in the instrument cluster. When the ignition switch is cycled (turned OFF and then ON), the air bag warning indicator will prove out by lighting for 6 seconds and then turn off.If a SRS fault exists, the air bag warning indicator will illuminate and remain illuminated for the rest of the key cycle.The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool.If the RCM requests illumination of the air bag warning indicator and the air bag warning indicator does not function, the instrument cluster module will automatically 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 warning indicator require repair. The RCM includes a backup power supply.This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is lost or damaged during impact.The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. A new RCM installed in a vehicle will flash lamp fault code (LFC) 54 until programmable module installation (PMI) has been carried out on the RCM.If a LFC is present after completing PMI, a fault is present in the SRS and on-demand DTCs must be retrieved and diagnosed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8684 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 RCM orientation is critical for proper air bag SRS operation. If a vehicle equipped with an SRS system has been involved in a Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8685 collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed 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. - When installing a new RCM, it is necessary to carry out programmable module installation (PMI). NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new 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 1. If installing a new restraints control module (RCM), carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the system. Vehicles with a center console 3. Remove the center console. Vehicles with bucket seats and no center console 4. Remove the 3 RCM push-nut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8686 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Install the RCM and 3 bolts. Tighten to 11 Nm (8 lb-ft). 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 (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8687 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats and no center console 6. Install the 3 RCM push-nut retainers and the RCM cover. Vehicles with a center console 7. Install the center console. All vehicles 8. Repower the SRS. Do not prove out the SRS at this time. 9. When installing a new RCM, carry out the steps necessary to complete programmable module installation (PMI). 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash. The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8688 exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous memory diagnostic trouble codes (DTCs) from the RCM. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8694 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8695 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8696 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8697 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8698 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8699 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8700 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8701 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8702 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8703 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8704 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8705 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8706 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 8711 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation Seat Belt: 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Page 8715 Seat Belt: Service and Repair 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. Move the driver seat to the most forward position. 2. Move the passenger seat to the most rearward position. 3. Remove the bolt and route the safety belt out from the seat. - To install, tighten to 55 Nm (41 lb-ft). 4. 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. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. 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. 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. 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 fault PIDs for an open circuit will be activated. For safety belt buckle pretensioner diagnostic information, refer Air Bag Systems. For safety belt buckle pretensioner disposal information, refer Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, 20 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 20 PERCENT SEAT Removal and Installation WARNING: 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 seat upright. 2. Remove the nut and safety belt buckle assembly from underneath the seat. - To install, tighten to 55 Nm (41 lb-ft). 3. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8721 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. 1. Pivot the 40 percent seat upward. 2. Remove the rearward screw (not shown) and seat side shield. - Release the pin-type retainer (not shown). 3. Remove the bolt and the safety belt buckle. - To install, tighten to 50 Nm (37 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8722 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 40 percent 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8723 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Third Row, 60 Percent Seat SAFETY BELT BUCKLE - THIRD ROW, 60 PERCENT SEAT Removal and Installation WARNING: 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. Fold the 60 percent seat down. 2. Position the load floor panels up. 3. Remove the bolt and safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 4. Fold the 60 percent seat up and remove the safety belt buckle assembly through the seat. 5. NOTE: - 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. 6. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8724 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. Position the seat upright. 2. Remove the nut and safety belt buckle assembly from underneath the seat. - To install, tighten to 55 Nm (41 lb-ft). 3. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, 40 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 40 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8725 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. Pivot the 40 percent seat upward. 2. Remove the rearward screw (not shown) and seat side shield. - Release the pin-type retainer (not shown). 3. Remove the bolt and the safety belt buckle. - To install, tighten to 50 Nm (37 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 - Third Row, 40 Percent Seat SAFETY BELT BUCKLE - THIRD ROW, 40 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8726 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 40 percent 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8727 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. Fold the 60 percent seat down. 2. Position the load floor panels up. 3. Remove the bolt and safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 4. Fold the 60 percent seat up and remove the safety belt buckle assembly through the seat. 5. NOTE: - 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. 6. Check the active restraint system for correct operation. Safety Belt Buckle and Pretensioner - 60 Percent SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8728 Removal 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. - 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 restraints control module (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 supplemental restraint system (SRS). 3. Remove the 60 percent front seat. 4. NOTE: Make note of the wire harness routing for installation. Remove the tie strap from the pretensioner. Disconnect the safety belt buckle switch electrical connector. - Disconnect the safety belt buckle pretensioner electrical connector. 5. Remove the nut and safety belt buckle pretensioner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8729 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 55 Nm (41 lb-ft). 3 Route the safety belt buckle switch and pretensioner electrical connectors as noted in removal. 2. Connect the electrical connectors. 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. Safety Belt Buckle and Pretensioner - 40 Percent SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT Removal and Installation WARNING: - 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. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8730 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. 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 restraints control module (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 supplemental restraint system (SRS). 3. Remove the 40 percent front seat. 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 tie strap from the pretensioner. Disconnect the safety belt buckle switch electrical connector. - Disconnect the safety belt buckle pretensioner electrical connector. 6. Remove the nut and safety belt buckle and pretensioner. - To install, tighten to 55 Nm (41 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. Safety Belt Buckle - Front, Center SAFETY BELT BUCKLE - FRONT, CENTER Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 8731 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. Move the seat to the most forward position. 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 8736 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 8739 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 8740 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair SAFETY BELT SHOULDER HEIGHT ADJUSTER 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 ALR 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. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install new D-ring cover and bolt. Position the safety belt guide to the lowest position. Remove the upper B-pillar trim panel. 2. Access the bolt behind the safety belt shoulder height adjuster trim cover in the following sequence. 1 Lower the safety belt shoulder height adjuster to the lowest point. 2 Fold the trim cover over. 3. Remove the safety belt shoulder height adjuster bolt. - To install, tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 8744 4. Remove the safety belt shoulder height adjuster. 1 Rotate the safety belt shoulder height adjuster downward to release the lower tab. 2 Remove the safety belt shoulder height adjuster. 5. NOTE: Make sure the safety belt webbing is not twisted prior to installation. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation 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 [ALR] feature) must be checked by a qualified technician to verify that the ALR 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 ALR 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 serious personal 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 automatic locking retractor (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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front SAFETY BELT RETRACTOR - FRONT Removal and Installation WARNING: 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 ALR 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8753 injury in collisions. 1. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a new D-ring cover. Remove the upper and lower B-pillar trim panels. 2. Release the 2 pin-type retainers and safety belt guide. 3. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: - Make sure the safety belt webbing is not twisted 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. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8754 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row and Third Row, Outboard SAFETY BELT RETRACTOR - SECOND ROW AND THIRD ROW, OUTBOARD Expedition/Navigator Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8755 Expedition EL/Navigator L (Part 1) Expedition EL/Navigator L (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8756 Safety Belt Retractor Sling, Expedition EL/Navigator L, 3rd 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. 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.ALR 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. Both retractors 1. Remove the rear quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8757 2. For RH 3rd row safety belt retractor, remove the 2 screws and position aside the auxiliary relay box, if equipped. Second row retractor (Expedition/Navigator) 3. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install new D-ring cover and bolt. Open the D-ring cover and remove the D-ring bolt. To install, tighten to 40 Nm (30 lb-ft). 5. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Second row retractor (Expedition EL/Navigator L) 6. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install new D-ring cover and bolt. Open the D-ring cover and remove the D-ring bolt. To install, tighten to 40 Nm (30 lb-ft). 7. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Third row retractor (Expedition/Navigator) 8. Open the D-ring cover and remove the D-ring bolt. - To install, tighten to 40 Nm (30 lb-ft). 9. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Third row retractor (Expedition EL/Navigator L) 10. Remove the sling cover and bolt. - To install, tighten to 40 Nm (30 lb-ft). 11. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Both retractors 12. 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. 13. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8758 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center SAFETY BELT RETRACTOR - SECOND ROW, CENTER 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 ALR feature, or any other safety belt function, is not operating correctly when Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8759 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 backrest trim cover. 2. Remove the seat backrest foam pad. 3. Remove the safety belt retractor cover foam. 4. Remove the 2 screws from the seat belt retractor cover and remove the cover. 5. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. Pinch and release the safety belt retractor guide from the seat backrest frame and remove the safety belt retractor. 7. NOTE: - Make sure the safety belt webbing is not twisted 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. 8. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8760 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row, Center SAFETY BELT RETRACTOR - THIRD ROW, CENTER 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 ALR 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 8761 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 third row 60 percent seat backrest trim cover. 2. Remove the seat backrest foam pad. 3. Remove the 4 screws from the seat belt retractor cover (2 shown). 4. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 5. Pinch to release the safety belt retractor guide and remove the safety belt retractor. 6. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 7. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Pretensioner, Driver > Page 8766 C3202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt Pretensioners Seat Belt Tensioner: Description and Operation Safety Belt Pretensioners SAFETY BELT PRETENSIONERS 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt Pretensioners > Page 8769 Seat Belt Tensioner: Description and Operation Attaching Safety Seats With Tether Straps 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 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner - 60 Percent Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner - 60 Percent SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT Removal 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. - 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 restraints control module (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 supplemental restraint system (SRS). 3. Remove the 60 percent front seat. 4. NOTE: Make note of the wire harness routing for installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner - 60 Percent > Page 8772 Remove the tie strap from the pretensioner. Disconnect the safety belt buckle switch electrical connector. - Disconnect the safety belt buckle pretensioner electrical connector. 5. Remove the nut and 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 55 Nm (41 lb-ft). 3 Route the safety belt buckle switch and pretensioner electrical connectors as noted in removal. 2. Connect the electrical connectors. 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner - 60 Percent > Page 8773 Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner - 40 Percent SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT Removal and Installation WARNING: - 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. - 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. 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 restraints control module (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 supplemental restraint system (SRS). 3. Remove the 40 percent front seat. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner - 60 Percent > Page 8774 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 tie strap from the pretensioner. Disconnect the safety belt buckle switch electrical connector. - Disconnect the safety belt buckle pretensioner electrical connector. 6. Remove the nut and safety belt buckle and pretensioner. - To install, tighten to 55 Nm (41 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 8781 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8787 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8788 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8789 Impact Sensor: Locations Safety Canopy Sensor, Driver 2 View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8790 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8791 Impact Sensor: Locations Safety Canopy Sensor, Passenger 2 View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 8792 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8795 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8796 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8797 C3314 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 8798 C3315 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 8799 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, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - 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. Install a new and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. For these vehicles, the SRS uses 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel, the second row sensors are located on each C-pillar. The side impact sensors are not interchangeable between the first and second row. Mounting orientation is critical for correct operation of all impact sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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. - The front impact severity sensor is located on the bottom of the lower radiator support. 1. Depower the system. 2. Disconnect the front impact severity sensor electrical connector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8802 - Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of the locator tab on the front impact severity sensor for installation. Remove the bolt and front impact severity sensor. To install, tighten to 11 Nm (8 lb-ft). 4. To install, reverse the removal procedure. 5. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8803 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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 restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8804 procedure again. - RH side shown, LH similar. 1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. NOTE: Make sure the second row safety belt retractor belt webbing is not twisted prior to installation. Remove the bolt and second row safety belt retractor anchor. To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips to access the C-pillar side impact sensor. 6. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the side impact sensor locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the side impact sensor bolt. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the removal procedure. 9. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8805 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 correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the sensor or any other damaged 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: - Avoid applying corrosion protection to any safety, mechanical and electrical parts, electric motors, speakers, door locks and drain holes. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a 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 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 (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8806 3. Separate the weathershield from the door 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 screws is critical for correct system operation. 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 tab for installation. Remove the 2 screws and side impact sensor. To install, tighten to 3 Nm (27 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 8811 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 8814 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 8815 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 (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Raise the driver seat and then position it to the rear of the track. 2. Depower the system. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the seat position sensor electrical connector and remove the seat position sensor and bracket. 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 8825 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > Customer Interest for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments Message Center Switches Inop/Other Errors Accessory Control Display: Customer Interest Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > Customer Interest for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments Message Center Switches Inop/Other Errors > Page 8835 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > Customer Interest for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments Message Center Switches Inop/Other Errors > Page 8836 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Accessory Control Display: All Technical Service Bulletins Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8842 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Control Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accessory Control Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8843 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8848 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8849 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8850 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair ANTENNA ISOLATOR MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the antenna cable connector, the antenna isolator module electrical connector, and the antenna isolator module-to-quarter glass connector. 3. Remove the stud and the antenna isolator module. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. Remove the audio unit. 2. Unclip the GPS antenna from the instrument panel brace and remove the GPS antenna. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 8862 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 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair Alarm System Transmitter: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER Removal and Installation 1. Remove the steering wheel. 2. Remove the 2 screws and the lower steering column shroud. 3. Remove the ignition lock cylinder cover. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be programmed into the instrument cluster again. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams C500 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8874 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: Up to 3 codes can be programmed. Once there are 3 programmed codes, any attempt to program additional codes will be unsuccessful. 1. Enter the permanent factory keyless entry keypad code. 2. NOTE: The locks should lock and unlock to indicate programming mode has been entered. 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 codes. 3. Within 5 seconds, enter the new 5-digit keypad code. The doors lock and unlock to confirm the new code is programmed. If the locks do not lock and unlock, the new code programming has not been successful and the procedure must be started from the beginning. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8875 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior mirror. 2. Remove the front door outer glass weatherstrip. - Disconnect the electrical connector. 3. Release the tabs and remove the keyless entry keypad. - Disconnect the keypad harness retaining clips from the weatherstrip. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming 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 scan tool or by carrying out the following steps. - Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Turn the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the transmitter. If the door locks do not respond for the programmed RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to respond, refer to Locks, Latches and Entry Systems. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 8880 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Programming the Autolock Feature Using the Door Lock Control Switch NOTE: - This feature can also be enabled or disabled using the message center switch functions, if equipped. - The autolock feature can be enabled or disabled independently of the auto-unlock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice within 5 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: - This feature can also be enabled or disabled using the message center switch functions, if equipped. - The auto-unlock feature can be enabled or disabled independently of the autolock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position.The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door unlock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 8881 Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: - The autolock feature can be enabled or disabled independently of the auto-unlock feature. - The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: - The auto-unlock feature can be enabled or disabled independently of the autolock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation Keyless Entry Transmitter: Service and Repair Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Move the seat, rear view mirrors, and adjustable pedals to the desired position. 2. Press the memory set switch SET button. 3. Within 5 seconds, press any button on the remote transmitter (except the PANIC button), and then press the appropriate memory set switch button. 4. Repeat Steps 1-3 for each remote transmitter to be programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation > Page 8884 Keyless Entry Transmitter: Service and Repair Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the memory set switch SET button. 2. Within 5 seconds, press any button on the remote transmitter that is to be deactivated (except the PANIC button), and then press the memory set switch SET button. 3. Repeat Steps 1 and 2 for each remote transmitter to be deactivated from the memory setting. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8889 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8890 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8891 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module sub-harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking aid module bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams C4015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams > Page 8895 Parking Assist Warning Indicator: Service and Repair PARKING AID SPEAKER Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Driver/Vehicle Information Display: Customer Interest Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8904 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8905 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Driver/Vehicle Information Display: All Technical Service Bulletins Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8911 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 8912 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8913 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8914 C253 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8915 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green (Expedition) items or white (Navigator) vacuum fluorescent, fixed units format, 2-line display integrated into the center of enable/ the instrument cluster and is controlled by the entry/ message center switches. There are two basic equipped), instrument cluster/message center configurations. items The first is the full function message center and can in be identified by the three button message center approximately switch located in the instrument panel center finish The panel. The second is the base cluster message decrease center and can be identified by the single reset can button located in the instrument cluster. Both approximately instrument cluster configurations display messages was based upon vehicle option content. The base cluster message center functions and menus listed below can be selected through the reset button by pressing and releasing the reset button to scroll through the menu items. The INFO items (trip A, trip B and average fuel economy) can be reset by holding the reset button for approximately 2 seconds. The SETUP items, (language, system configurable items [autolamps, autolock, auto unlock etc.]) can be reset by holding the reset button for approximately 2 seconds when the selected menu item is displayed. Refer to the Owner's Literature for complete operating instructions for both the full function message center and the base instrument cluster message center. The message center provides the following features: - Information displays - Setup displays - System check messages - System warning messages The full function message center features and menus listed below can be selected through a set of 3 buttons: - INFO - SETUP - RESET Message Center Configuration The message center has the capability to configure items such as oil life, oil life start value, language, units (English or metric), autolamp delay, to enable/disable a variety of options such as easy entry/easy exit (if equipped) and air suspension (if equipped), or to carry out calibrations/settings on items such as the compass. The oil life is displayed in percent and is preset to a maximum of approximately 8,000 km (5,000 miles) or 180 days. The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% decrements down to 10%. On configurable items such as parking aid on/off and air suspension on/off (if equipped) the message center indicates the appropriate selection (ON/OFF) by bracketing the selection. An example is as follows: PARKING AID OFF. The parking aid is enabled or on in the previous example. If the driver selects the parking aid off, the display would be: PARKING AID ON . Reconfigurable Telltale Indicators The message center displays reconfigurable telltale indicators in the RH side of the display area. Reconfigurable telltale indicators replace indicators that have been typically displayed in the instrument cluster and use the same iconic representation. Compass and Outside Air Temperature Displays The message center provides a compass display and uses directional information sent from a compass module, located on the underside of the inside rear view mirror. The message center provides an outside air temperature display on vehicles that are not equipped with electronic automatic temperature control (EATC). 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 - Outside air temperature display (if equipped) - Compass - Distance to empty (DTE) - Average fuel economy - Instantaneous fuel economy - Blank display Setup Displays The setup displays are timed modes and terminate after a finite interval.The setup display modes are: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8916 - System check - Oil life - Units English/metric - Autolamp delay in seconds (if equipped) - Easy entry/easy exit seat on/off (if equipped) - Air suspension on/off (if equipped) - Autolocks on/off (if equipped) - Power liftgate on/off (if equipped) - Power running boards auto/off/out (if equipped) - Compass zone - Compass calibration - Language System Check The system check provides a check of all the monitored systems on the vehicle. The system check scrolls through each of the monitored systems and provides a visual indication to report out the status of each system. The message center displays OK for approximately 2 seconds if the system check does not detect a fault in the system and displays a warning message for approximately 2 seconds if the system check detects a fault in the system. Press the RESET button to scroll through the system check messages. The system check messages are: OIL LIFE - CHARGING SYSTEM - WASHER FLUID LOW - DOOR STATUS - LIFTGATE/GLASS - BRAKE FLUID LEVEL - TIRE PRESSURE SYSTEM (if equipped) - AIR SUSPENSION SYSTEM (if equipped) - FUEL LEVEL System Warning Messages The system warning messages alert the operator to possible problems or malfunctions in the vehicle operating systems. The message center displays the last selected feature if there are no additional warning messages. Once a warning message has been displayed, the message must be acknowledged to allow full functionality of the message center. Press the RESET to acknowledge and clear the warning message. The warning messages are divided into 4 categories: - Cannot be cleared until the condition is corrected. - Reappear on the display 10 minutes from the reset if the condition has not been corrected. - Do not reappear until an ignition OFF-ON cycle has been completed. - Reappear if the condition clears then reoccurs within the same ignition cycle ON-OFF cycle. The warning display that cannot be reset is: PARK AID ON/OFF The warning messages that reoccur after 10 minutes are: CHECK BRAKE SYSTEM - XXX MILES (km) TO E FUEL LOW - PARK BRAKE ENGAGED The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: BRAKE FLUID LEVEL LOW - CHECK PARK BRAKE - WASHER FLUID LEVEL LOW - OIL CHANGE REQUIRED - XXX% OIL LIFE CHANGE SOON - CHECK AIR SUSPENSION SYSTEM (if equipped) The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: DRIVER DOOR AJAR - PASSENGER DOOR AJAR - REAR LEFT DOOR AJAR - REAR RIGHT DOOR AJAR - LIFTGATE/GLASS AJAR - CHECK CHARGING SYSTEM - TIRE PRESSURE SENSOR FAULT (if equipped) - LOW TIRE PRESSURE (if equipped) - TIRE PRESSURE MONITOR FAULT (if equipped) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8917 - 4X4 SHIFT IN PROGRESS (if equipped) - AIR SUSPENSION OFF (if equipped) The message center displays warning messages that indicate a system state during the operation of the four wheel drive (4WD) system (late build only). The displayed warning messages are as follows: FOR 4X4 STOP VEHICLE (if equipped) - FOR 4X4 LOW APPLY BRAKE (if equipped) - FOR 4X4 LOW SHIFT TO N (if equipped) - TO EXIT 4X4 LOW STOP VEHICLE (if equipped) - TO EXIT 4X4 LOW APPLY BRAKE (if equipped) - TO EXIT 4X4 LOW SHIFT TO N (if equipped) The message center displays warning messages that indicate a system state during repair procedures related to the tire pressure monitoring system (TPMS). The displayed warning messages are as follows: TRAIN LEFT TIRE (if equipped) - TRAIN LEFT REAR TIRE (if equipped) - TRAIN RIGHT FRONT TIRE (if equipped) - TRAIN RIGHT REAR TIRE (if equipped) - TRAIN SPARE TIRE (if equipped) - TRAINING COMPLETE (if equipped) - TIRES NOT TRAINED-REPEAT (if equipped) The message center displays warning messages that indicate a system state during repair procedures related to the compass display. The displayed warning messages are as follows: RESET FOR ZONE SETTING - ZONE XX RESET = CHANGE - RESET FOR CALIBRATION - CIRCLE SLOWLY TO CALIBRATE - CALIBRATION COMPLETED - COMPASS DATA ERROR The message center displays warning messages that indicate a system state during repair procedures related to the oil life and oil life start value. The displayed warning messages are as follows: OIL LIFE XXX% HOLD RESET = NEW - OIL LIFE SET TO XXX% Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test: - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center is an integral part of the instrument cluster that receives and acts upon much of the same information that is input and used to operate the instrument cluster gauges, indicators, warning indicators and reconfigurable telltale indicators. The message center, located in the center of the instrument cluster is a vacuum fluorescent 2-line display. The message center electronic functions use both hardwired, and the controller area network (CAN) circuitry to transmit and receive information. Whenever conditions are present that require a warning message, the message center replaces the last selected display with the new warning display. Once the message is reset or cleared, the message center returns to the last selected display. If multiple warnings are present, the message center displays each warning for approximately 4 seconds. Warning messages are also generally associated with other observable instrument cluster indications. For example, when the LH front door is opened, the message center displays the message DRIVER DOOR AJAR along with the door ajar reconfigurable telltale indicator. This allows the message center to be a more informative supplement to the instrument cluster gauges and indicators. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8920 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. Instrument Cluster Messages NOTE: Whenever a message is suspected as missing, confirmed by a missing message DTC, it is important to look for other symptoms that may also be present in the instrument cluster and throughout the vehicle. Once a DTC is set in the instrument cluster it may be helpful to review the complete message list available in Information Bus (Module Communications Network) to see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also be set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems. The instrument cluster uses input messages from other modules to control the gauges, informational indicators, warning indicators and reconfigurable telltale indicators over the communication networks. If a required message is missing or invalid for less than 5 seconds, the gauge or indicator that requires the message remains at the last commanded state based upon the last known good message. For example, if the message is missing the O/D off status for less than 5 seconds and the O/D off indicator was ON (O/D cancelled), the indicator remains in the ON state until the next good message is received. If the message remains missing or invalid for greater than 5 seconds, the instrument cluster sets a U-code DTC and the output becomes a default action for the indicator or gauge. Each indicator or gauge utilizes a different default strategy depending on the nature of the indication. Refer Instrument Panel, Gauges and Warning Indicators. for further descriptions of the default action specific to each indicator or gauge. If the messaged input to the cluster returns at any time, the normal function of the gauge or indicator resumes. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8921 B1255-B2097 / U2013 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8922 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8923 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8924 Symptom Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8925 Symptom Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8926 Symptom Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8927 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 is located in the center of the instrument cluster between the tachometer and the speedometer in the vacuum fluorescent display area. The message center is integral to the instrument cluster and uses the same voltage supply as the instrument cluster. The RUN/START voltage is supplied to the instrument cluster on circuit CBP29 (WH/VT) and the keep alive B+ voltage is received on circuit SBP26 (YE/RD). The instrument cluster ground is received through circuit GD133 (BK). The message center functionality is controlled through the message center switches, which are hardwired to the instrument cluster through the input circuit CMC29 (GN/VT) and the return circuit VMC29 (YE). Possible Causes - Message center switches - Instrument cluster Test B: The Message Center Switch Does Not Operate Correctly PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY B1-B2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8928 B2-B4 Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster through the input circuit CMC29 (GN/VT) and the return circuit VMC29 (YE). There are 3 message center switch buttons with each button operating a switch that uses different resistance values. The instrument cluster sends out a reference voltage to the message center switch on the input circuit and monitors the input voltage when a message center switch button is pressed. The input voltage will vary depending upon the resistance of each button, providing a specific indication to the instrument cluster which switch is pressed. Possible Causes - Circuit CMC29 (GN/VT) open or short to ground - Circuit VMC29 (YE) open or short to ground Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8929 - Message center switch - Instrument cluster Test C: The Compass Is Inoperative PINPOINT TEST C: THE COMPASS IS INOPERATIVE C1-C3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8930 C3-C4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8931 C5 Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP31 (BU/OG) and is grounded through circuit GD133 (BK). The compass sensor module communicates the vehicle direction to the instrument cluster through the compass communication data plus circuit VMC31 (YE/GN) and compass communication data minus circuit VMC30 (BU/GY). DTC B2097 - sets in continuous memory if the instrument cluster detects invalid data sent from the compass module. DTC U2013 - is a continuous memory and on-demand DTC that sets if the instrument cluster is missing the compass data from the compass module. If the instrument cluster fails to receive the compass data, the instrument cluster sets DTC U2013 and defaults the compass display to (----). Possible Causes - Fuse - Circuit CBP31 (BU/OG) open - Circuit GD133 (BK) open - Circuit VMC30 (BU/GY) open or short to ground - Circuit VMC31 (YE/GN) open or short to ground - Compass sensor module Test D: The Compass Is Inaccurate PINPOINT TEST D: THE COMPASS IS INACCURATE D1 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster through the compass communication data plus circuit Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8932 VMC31 (YE/GN) and compass communication data minus circuit VMC30 (BU/GY). The magnetic fields generated by the earths north and south poles are divided into zones that differ from each other with respect to how the magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and become noticeable across multiple zones. The compass zone must be set to the correct zone for the compass to read accurately. Factors within the vehicle may affect the ability of the compass module to accurately read the magnetic north. Calibrating the compass allows the compass module to compensate for vehicle factors that influence the accuracy of the compass. NOTE: Outside factors such as bridges, steel structures, tall buildings and power lines also affect compass accuracy. Possible Causes - Compass sensor module - Zone setting - Calibration Test E: The Outside Air Temperature Sensor Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE SENSOR DOES NOT OPERATE CORRECTLY E1-E4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8933 E4-E5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8934 E6-E7 Normal Operation The outside air temperature sensor is mounted on the radiator core support in front of the radiator and A/C condenser and is hardwired to the instrument cluster through input circuit VH407 (YE/GN) and return circuit VMC29 (YE). The instrument cluster provides a reference voltage to the ambient air temperature sensor and monitors the change in voltage resulting from changes in resistance as determined by outside air temperature. When the engine has been off for 2 hours, or the engine temperature is cold, the instrument cluster displays the current outside air temperature as measured by the ambient air temperature sensor. When the time is less than 2 hours, or if the engine is not cold, the instrument cluster takes a reading of the current temperature and compares the current reading against the last reading at key off. If the temperature is less than the last key off temperature reading, the instrument cluster displays the current temperature. If the temperature is greater than the last key off temperature reading, the instrument cluster displays the last key off temperature reading until the ambient air temperature has had time to stabilize with vehicle movement. DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an open on the outside air temperature sensor input, circuit VH407 (YE/GN). If the instrument cluster detects an open on the outside air temperature input, the instrument cluster defaults the display to 23.89°C (75°F). DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short to ground on the outside air temperature sensor input, circuit VH407 (YE/GN). If the instrument cluster detects a short to ground on the outside air temperature input, the instrument cluster defaults the display to 23.89°C (75°F). Possible Causes - Circuit RH111 (GY/BU) open - Circuit VH407 (YE/GN) open, short to voltage or ground - Circuit VMC29 (YE) open or short to voltage - Outside air temperature sensor - Instrument cluster Test F: The Parking Aid On/Off Warning Is Inoperative PINPOINT TEST F: THE PARKING AID ON/OFF WARNING IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8935 F1-F5 Normal Operation The parking aid on/off status is sent from the parking aid module to the instrument cluster over the medium speed controller area network (MS-CAN) communication bus lines. When the RESET button is pressed, the instrument cluster sends a query to the parking aid module, requesting a system status. The parking aid module responds to the instrument cluster with the status of the system, either on or off. If the return status message is missing or corrupted, the instrument cluster does not display the brackets around either the ON or OFF selection. Possible Causes - Instrument cluster configuration - Parking aid system - Instrument cluster Test G: The Check Air Suspension or Air Suspension Off Warning Is Inoperative PINPOINT TEST G: THE CHECK AIR SUSPENSION OR AIR SUSPENSION OFF WARNING IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8936 G1-G3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8937 G4-G6 Normal Operation The air suspension on/off status is sent from the air suspension module to the instrument cluster over the high speed controller area network (HS-CAN) communication bus lines. When the RESET button is pressed, the instrument cluster sends a query to the air suspension module, requesting a system status. The air suspension module responds to the instrument cluster with the status of the system, either on or off. If the return status message is missing or corrupted, the instrument cluster does not display the brackets around either the ON or OFF selection. Possible Causes - Instrument cluster configuration - Air suspension system - Air suspension module - Instrument cluster Test H: The 4X4 Shift In Progress Warning Is Inoperative PINPOINT TEST H: THE 4X4 SHIFT IN PROGRESS WARNING IS INOPERATIVE H1-H4 Normal Operation The four wheel drive (4WD) control module sends the instrument cluster a message over the high speed controller area network (HS-CAN) communication bus lines when the 4WD system is in the process of shifting out of two wheel drive (2WD) and has not yet fully shifted into 4x4 high, 4x4 low or 4x4 auto. Once the shift is completed, the 4WD control module removes the 4x4 shift in progress message and sends a new message to turn on the applicable reconfigurable telltale indicator. Possible Causes - Instrument cluster configuration - 4WD system - 4WD control module - Instrument cluster Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Oil Life Reset - Message Center Cluster OIL LIFE RESET - MESSAGE CENTER CLUSTER NOTE: - The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE =80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster OIL LIFE RESET - BASE INSTRUMENT CLUSTER NOTE: - All message center functions are carried out using the single stem reset button in the instrument cluster. - The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster OIL LIFE START VALUE - MESSAGE CENTER CLUSTER NOTE: - The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER NOTE: - All message center functions are carried out using the single stem reset button in the instrument cluster. - The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8940 Driver/Vehicle Information Display: Removal and Replacement MESSAGE CENTER SWITCH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8941 Removal and Installation Expedition 1. Pull the instrument panel center finish panel straight out to release the retaining clips. Navigator 2. NOTE: The transmission selector lever bezel is held in place by 4 tabs that are located in the shifter assembly. Remove the transmission selector lever bezel. 3. Open the floor console compartment door and pull the floor console finish panel straight up to release the retainer clips. 4. Remove the 2 screws and pull the instrument panel center finish panel straight out to release the retainer clips. - Position the instrument panel center finish panel aside. All vehicles 5. Disconnect the electrical connectors. 6. Press the 4 retaining tabs and remove the message center switch from the center instrument panel finish panel. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8942 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams Auxiliary Input / Output Jack: Diagrams C2362 C3312 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 8947 Auxiliary Input / Output Jack: Service and Repair AUDIO INPUT JACK Removal and Installation Expedition 1. Remove the instrument panel center finish panel. Navigator 2. Remove the front floor console center finish panel. All vehicles 3. Release the tabs and remove the audio input jack. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams C949 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8951 DVD Player: Service and Repair DIGITAL VERSATILE DISC (DVD) PLAYER Removal NOTE: Programmable module installation (PMI) only needs to be carried out if the DVD player is being replaced. 1. Upload the DVD player configuration to the scan tool. 2. NOTE: Open the DVD player display. Remove the 4 screws. 3. Remove the DVD player. - Pull down on the sides of the DVD player to disengage the clips from the bracket. - Using a suitable tool, push the rear most U-hook forward and release the U-hooks. - Hang the DVD player on the J-hooks and disconnect the electrical connector. - Remove the DVD player from the J-hooks. Installation 1. Hang the DVD player on the J-hooks. 2. Connect the electrical connector. 3. Remove the DVD player from the J-hooks. 4. NOTE: Tilt the DVD player, as necessary, to align it correctly. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8952 Align the left side guide pin with the left side locating hole. 5. Lift up the right side of the DVD player and engage the U-hooks. 6. Install the 4 screws. 7. Push on the left and right sides of the DVD player to engage the clips. 8. Download the DVD player configuration from the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The universal transmitter is an integral part of the LH sun visor and provides a convenient way to substitute up to 3 hand-held transmitters with a single built-in device. The universal transmitter can learn the radio frequency codes of most current transmitters. The universal transmitter: - operates garage doors, gates and home/office lighting and security systems. - learns and transmits the radio frequency of up to 3 hand-held transmitters from any of the systems mentioned above. - is powered by the vehicle battery and charging system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. 2. Visually inspect the following for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Universal transmitter - 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. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8958 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8959 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 CLN09 (YE/GN) and ground on circuit GD150 (BK/WH). Possible Causes - Receiver unit - Universal transmitter Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8960 Garage Door Opener Transmitter: Component Tests and General Diagnostics Universal Transmitter Programming 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 universal 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. Failure to follow these instructions may result in personal injury. 1. Verify the hand-held transmitter is operative. 2. Prepare for programming the universal transmitter by erasing all 3 channels by holding down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select 1 of the 3 universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25-51 mm (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 2 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 pressing the hand-held transmitter button every 2 seconds. 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. To operate, press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. 8. To program additional hand-held transmitters repeat Steps 3-6. 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. 3 Press the training button on the garage door opener receiver for 1-2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and press the button to confirm the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels ERASING CHANNELS 1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. To erase all 3 programmed channels, hold down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8965 Memory Positioning Module: Diagrams C341A C341B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8966 C341C C341D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8967 C341E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8974 C3246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop Navigation System: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek Inop TSB 06-25-3 11/30/06 PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge, Expedition, Explorer Sport Trac, F-150 LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY feature filters out radio stations that do not fit a selected category of radio programming like: Top 40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and no stations are found under the selected category. ACTION Follow the Service Procedure to identify the PTY (Program Type) setting. SERVICE PROCEDURE To confirm the PTY (Program Type) setting use the following steps: 1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW OPTIONS buttons). 2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See Figure 1) 3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY feature by pushing the PTY button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8979 DEALER CODING CONDITION BASIC PART NO. CODE 18806 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8980 Navigation System: Technical Service Bulletins Navigation System - Service Tips TSB 06-23-15 12/06/06 SERVICE TIPS FOR OPTIONAL NAVIGATION SYSTEM RADIO FORD: 2003-2007 Expedition 2005-2007 Escape Hybrid MERCURY: 2006-2007 Mariner Hybrid This article supersedes TSB 06-5-15 to update the vehicle model years. ISSUE Some 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid, and 2003-2007 Expedition vehicles equipped with optional Navigation systems may exhibit concerns of the Navigation display locking up, periodic rebooting concerns and a lack of accuracy of location information. Escape Hybrids may also experience loss of HEV power flow display and fuel economy screen displays. ACTION The following Service Procedure will assist with diagnosis and prevent the replacement of good components. SERVICE PROCEDURE 1. Navigation radio software update procedures: Under no circumstances should you use an update CD on an Escape Hybrid. On 2003-2004 model year Expeditions, do not update the Radio software unless the update disc is part of a complete set of Navigation Map Discs/DVD. Only those map discs should be used with the update included with the set. The map CD's and the update disc's are matched sets. The table above shows compatible audio / navigational software version numbers for the Hybrid Escape and Expedition navigation radios. These software version numbers can be accessed through a menu on the navigational unit, refer to 2006 Expedition Workshop Manual, Section 419-07 for more details. This table may be helpful in determining whether the software on a particular navigational unit has been incorrectly updated in the past. NOTE DO NOT REPROGRAM SOFTWARE UNLESS A CUSTOMER HAS PURCHASED A MAP UPGRADE AND IT IS REQUIRED FOR AN 03/04 EXPEDITION. 2. Hybrid fuel economy / PowerFlow screen display issues: These functions are unique to the HEV navigation radio. Following these tips will prevent the unnecessary replacement of good parts. ^ If the PowerFlow screen or Fuel Economy screens do not display, or have no information shown, the radio itself is not likely defective Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8981 ^ The wiring to the gateway-SCP module (also referred to as the Audio Control Protocol Module) and the gateway-SCP module itself should be inspected. Specifically, Connectors C2294 (A and B) at the Gateway module, and Connector C229c at the navigation radio should be checked for issues such as pushed out pins, connector fully seated and pin fit ^ Continuity should be measured on circuits 833, 856, and 1068 between the connectors mentioned above ^ Powers and grounds to the gateway-SCP module should also be checked ^ The gateway module itself should also be inspected for damage before replacing the radio ^ If another HEV unit is available, swapping the gateway-SCP module can determine if the module is functioning correctly 3. Navigation disc care and handling: For some concerns of the navigation display locking up, periodic rebooting, blank screen, no vehicle cursor display, vehicle cursor display with no map screen display, and inability to eject disc maybe caused by dirty or damaged CDs. In most cases dirty or scratched map CDs are the likely cause of the listed concerns and can be detected with the "CDROM status" diagnostic function test. NOTE INFORMATION DISCS ARE MOR[ SENSITIVE TO CLEANLINESS AND CONDITION THAN AUDIO DISCS. TO CLEAN DISCS, USE A SOFT, NONABRASIVE, LINT FREE CLOTH. DO NOT CLEAN THE DISC IN A CIRCULAR MOTION. CLEAN THE DISC FROM THE INNER HUB TO THE OUTSIDE TO MINIMIZE SCRATCHING. DO NOT USE A CLEANING SOLUTION ON DISCS. IF POSSIBLE, TRY KNOWN GOOD DISCS FROM ANOTHER VEHICLE IN SUSPECT UNIT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18K931 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions Navigation System: 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8984 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8985 orientation. 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8986 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8987 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8988 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8989 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8990 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8991 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8992 Navigation System: 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8993 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8994 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8995 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8996 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8997 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8998 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8999 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9000 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9001 Navigation System: 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. 130-1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9002 130-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9003 130-3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9004 130-4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9005 130-5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9006 130-6 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9007 130-7 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9008 130-8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9009 130-9 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9010 130-10 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9011 130-11 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9012 130-12 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9013 130-13 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9014 130-14 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9015 130-15 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9016 130-16 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9017 130-18 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9018 130-19 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 130-20 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Page 9020 Navigation System: Description and Operation NAVIGATION SYSTEM The vehicle navigation system audibly and visually guides the user to a selected destination. The system uses a global positioning system (GPS) antenna, a vehicle speed input, and other sensor information to accurately establish the vehicle position. The audio unit provides the visual and audible instructions of the maneuvers required to arrive at the pre-entered destination. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Navigation System: Initial Inspection and Diagnostic Overview 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 the fault is visually evident, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. NOTE: Do not press any buttons on the audio unit while the audio unit is carrying out the self-test. Carry out the network test: If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the audio unit. 9. If the DTCs retrieved are related to the concern, go to the Audio Unit Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, go to the Navigation Audio Unit Self-Diagnostics. See: Reading and Clearing Diagnostic Trouble Codes Principles of Operation PRINCIPLES OF OPERATION Navigation System The navigation module is integrated in the audio unit and controls the operation and the interface between the user, the vehicle subsystems, and the external components. The navigation audio unit is on the medium speed controller area network (MS-CAN) and can be diagnosed with a scan tool. The vehicle navigation system guides the user to a pre-entered destination. A map digital versatile disc (DVD) stored in the navigation audio unit is used for calculating the vehicle course. The audio unit display audibly and visually instructs the user of the maneuvers required to arrive at the destination entered. A voice recognition system allows the user to interface with the system without using the touch screen. A microphone located in the rear view mirror provides a direct input to the navigation module. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9023 In order to calculate initial vehicle position, the global positioning system (GPS) antenna is used to track several available satellites simultaneously. The vehicle speed signal (VSS) and transmission gear selected signal are received by the navigation audio unit through the MS-CAN. These signals are used to increase the accuracy of the displayed course. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9024 Navigation System: Reading and Clearing Diagnostic Trouble Codes NAVIGATION AUDIO UNIT SELF-DIAGNOSTICS The navigation system provides on-board diagnostics to assist with diagnosing a concern. To carry out self-diagnostics, do the following: Press and hold presets 3 and 6 simultaneously for 3 seconds. Press the End Test button on the screen to exit the speaker walk-around test. The following options are available using the on-screen buttons: - On Demand Self Test: provides internal self-test diagnostics and displays all the diagnostic trouble codes (DTCs) resulting from the self-test. - View DTC's: provides a list of all DTCs currently stored in memory. - Configuration Status: displays the current navigation audio unit configuration. - System Info: displays the navigation audio unit part number and software information. - GPS Info: provides satellite and current vehicle information. - Speaker Walk Test: performs the speaker walk-around test. - Multi-disc Test: checks the status of the compact disc (CD) player mechanism. - Display Test: allows checking of the screen colors, and allows checking individual sectors of the touch screen. - Hardkey Test: provides the status (active/not active) of the audio unit buttons and touch screen. - Radio Signal Strength: tests the antenna signal. - Exit Diagnostics: exits diagnostics and returns to the main navigation screen. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9025 Navigation System: Diagnostic Trouble Code Descriptions B1117-B1119 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9026 B1136-B2656 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9027 B2924-B2965 / C1992 / P0812 / U0140-U0196 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9028 U0197-U2473 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9029 Navigation System: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9030 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9031 Navigation System: Pinpoint Tests Test A: Navigation System Does Not Operate Correctly - No Global Positioning System (GPS) Antenna Signal PINPOINT TEST A: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - NO GLOBAL POSITIONING SYSTEM (GPS) ANTENNA SIGNAL A1-A4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9032 A4-A5 Normal Operation The GPS antenna provides information from the GPS satellite system to the GPS receiver in the audio unit. This information is used to calculate vehicle position and direction of travel. B2204 - sets when an open, short to ground, or short to voltage is detected in the GPS antenna circuit. Possible Causes - GPS antenna - Audio unit Test B: Navigation System Does Not Operate Correctly - The Audible Switch Feedback Is Inoperative PINPOINT TEST B: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - THE AUDIBLE SWITCH FEEDBACK IS INOPERATIVE B1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9033 B1-B2 Normal Operation The audible switch feedback settings are controlled by the audio unit. The notification can be set to ALL, TOUCH SCREEN, or NONE, depending on user preference. Possible Causes - Audible switch feedback setting - Audio unit Test C: Navigation System Does Not Operate Correctly - The Voice Guidance Is Inoperative/Does Not Operate Correctly PINPOINT TEST C: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - THE VOICE GUIDANCE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9034 C1-C4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9035 C4-C7 Normal Operation For the Audiophile navigation system, the audio unit provides voice-assisted route guidance through the front speakers. For the THX(R) navigation system, the audio unit sends voice guidance audio signals to the THX(R) amplifier through circuits RMN14 (GY/BN) and VMN14 (WH/VT). The voice-assisted route guidance is broadcast through the instrument panel speaker. For all navigation audio systems, the volume of the voice guidance is controlled by the audio unit. Possible Causes - Circuit RMN14 (GY/BN) open, short to ground or voltage Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9036 - Circuit VMN14 (WH/VT) open, short to ground or voltage - THX amplifier - Audio unit Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Page 9037 Navigation System: Adjustments NAVIGATION SYSTEM CALIBRATION 1. Access the current set of regional map digital versatile discs (DVDs). 2. Start the vehicle. 3. Turn on the audio unit. 4. Insert the appropriate regional map DVD into the DVD slot in the audio unit. 5. Press the NAV button. 6. Press ACCEPT after reading the disclaimer. 7. Press the MAP button. 8. Road test the vehicle until the red compass heading indicator turns green/white. 9. Leave the map DVD in the audio unit. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Testing and Inspection > Page 9038 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 9043 C2003 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 9055 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pedal Positioning Switch: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 9061 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9062 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9063 C2089 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9064 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9066 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 9072 Amplifier: Diagrams THX Amplifier C2364A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 9073 C2364B C2364C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 9074 Amplifier: Service and Repair AUDIO AMPLIFIER - THX(R) THX(R) Amplifier Lower Attachment Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 9075 THX(R) Amplifier Upper Attachment Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 9076 THX(R) Amplifier Removal Routing Removal and Installation 1. Remove the audio unit. 2. Remove the necessary attachments and move the center console 5 cm (2.0 in) towards the rear of the vehicle. 3. Disconnect the THX(R) amplifier electrical connectors. 4. Remove the 2 lower THX(R) amplifier nuts. - To install, tighten to 9 Nm (80 lb-in). 5. CAUTION: The THX(R) amplifier is heavy. Be sure to support the amplifier during removal, or damage to the vehicle may occur. Remove the 2 upper THX(R) amplifier nuts. To install, tighten to 9 Nm (80 lb-in). 6. Remove the THX(R) amplifier. - Route the THX(R) amplifier down and towards the passenger side of the vehicle. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop Radio/Stereo: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek Inop TSB 06-25-3 11/30/06 PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge, Expedition, Explorer Sport Trac, F-150 LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY feature filters out radio stations that do not fit a selected category of radio programming like: Top 40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and no stations are found under the selected category. ACTION Follow the Service Procedure to identify the PTY (Program Type) setting. SERVICE PROCEDURE To confirm the PTY (Program Type) setting use the following steps: 1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW OPTIONS buttons). 2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See Figure 1) 3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY feature by pushing the PTY button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 9081 DEALER CODING CONDITION BASIC PART NO. CODE 18806 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 9082 C3290 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 9083 Radio/Stereo: Service and Repair SATELLITE RADIO RECEIVER Removal and Installation 1. Remove the center console. 2. Remove the 4 screws and the satellite radio receiver. - Disconnect the electrical connectors. - To install, tighten the screws to 8 Nm (71 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Auxiliary Audio Module Remote Control: Service and Repair Auxiliary Audio Module AUXILIARY AUDIO MODULE Removal and Installation Navigator 1. Remove the floor console cupholders. 2. Remove the 2 screws securing the rear trim panel to the floor console. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Auxiliary Audio Module > Page 9088 3. Remove the 2 screws under the armrest cover. All vehicles 4. Remove the bolt and the center console rear trim panel. - Disengage the pin-type retainers. - Disconnect the auxiliary audio module electrical connector. 5. Remove the auxiliary audio module. - Remove the 4 screws. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Auxiliary Audio Module > Page 9089 Remote Control: Service and Repair Steering Wheel Controls STEERING WHEEL CONTROLS Removal and Installation 1. NOTE: - It is not necessary to remove the driver air bag module during this procedure. - When removing the steering wheel controls, disengage the RH side of the controls first. Using an appropriate tool, pry the steering wheel controls out of the steering wheel. 2. NOTE: Do not allow the electrical connector to fall back into the steering wheel. Remove the steering wheel controls. Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control Module, Audio - Stereo > Component Information > Locations View 151-19 (Center Console - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control Module, Audio - Stereo > Component Information > Locations > Page 9093 C3077 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker C2359 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9099 C513 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9100 C613 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9101 C4212 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9102 Speaker: Diagrams C2359 C513 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9103 C613 C4212 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9104 C523A C523B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9105 C570 C612A Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9106 C612B C647 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9107 C702 C802 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 9108 C4337 C4338 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 9109 Speaker: Description and Operation SPEAKERS The following speaker configurations are available: - Base/Premium Two front door speakers - Two rear door speakers - Two sail-mounted tweeter speakers - Audiophile Two front door speakers - Two rear door speakers - Two sail-mounted tweeter speakers - Two subwoofers (mounted in a single enclosure) - THX(R) Two front door speakers - Two rear door speakers - Three front center imaging speakers (mounted in a single enclosure) - Two D-pillar rear imaging speakers (part of the D-pillar trim panels) - Two subwoofers (mounted in a single enclosure) The THX(R) audio system is available with either the 6-CD or navigation audio unit. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 9112 Front or rear door speaker 3. Remove the 4 screws and the speaker. - Disconnect the electrical connector. All speakers 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 9113 Speaker: Service and Repair Subwoofer Speaker SUBWOOFER SPEAKER Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the 2 nuts, the bolt, and the subwoofer speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 9114 Speaker: Service and Repair Instrument Panel Speaker INSTRUMENT PANEL SPEAKER Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the 4 screws and the instrument panel speaker cover. 3. Remove the 4 screws and the instrument panel speaker. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 9115 Speaker: Service and Repair Quarter Panel Speaker QUARTER PANEL SPEAKER Removal and Installation 1. Remove the D-pillar trim panel. 2. Remove the 4 screws and the speaker bracket. 3. Separate the quarter panel speaker assembly from the D-pillar trim panel. 4. Remove the 2 screws and the quarter panel speaker. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9121 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9122 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9123 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Service and Repair Antenna Control Module: Service and Repair ANTENNA ISOLATOR MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the antenna cable connector, the antenna isolator module electrical connector, and the antenna isolator module-to-quarter glass connector. 3. Remove the stud and the antenna isolator module. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9130 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9131 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9132 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module sub-harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking aid module bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Remote Control Module, Audio - Stereo > Component Information > Locations View 151-19 (Center Console - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Remote Control Module, Audio - Stereo > Component Information > Locations > Page 9136 C3077 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 9149 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 9155 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9161 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9162 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9168 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9169 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9170 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9171 C2089 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9172 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9173 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 9174 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 9179 C2142 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9184 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9185 orientation. 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9186 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9187 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9188 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9189 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9190 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9191 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9192 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9193 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9194 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 Trailer Connector: Connector Views C4098 C4099 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Trailer Hitch Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 9208 WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a rear end collision. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the trailer hitch rear bumper cover trim panel, if equipped. 3. Remove the 4 trailer lighting plug cover bolts. 4. Remove the trailer lighting plug. - Position the plug away from the trailer hitch. - Disconnect the electrical connector. - Remove the trailer lighting plug. 5. Remove the electrical connector from the trailer hitch and unclip the harness from the retainers on the frame. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 9209 6. Remove the 4 trailer hitch side mounting bolts (2 each side). - To install, tighten to 175 Nm (129 lb-ft). 7. Remove the 4 trailer hitch lower mounting bolts (2 each side) and remove the trailer hitch. - To install, tighten to 275 Nm (203 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 9210 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9215 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9216 orientation. 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9217 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9218 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9219 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9220 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9221 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9225 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9226 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9227 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9231 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9232 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 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 (2007)) 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. 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 5 (40A) (trailer electric brake controller) - 12 (25A) (trailer tow parking lamps) - 13 (30A) (trailer tow battery charge relay switch side) - 34 (25A) (trailer tow turn relays) - 63 (15A) (trailer tow reversing lamps) - Smart junction box (SJB) fuse 42 (10A) (trailer tow battery charge relay coil) - Circuitry - Trailer tow turn/stop relays - Trailer tow battery charge relay - Trailer tow parking lamp relay - Trailer brake control module - Trailer - SJB 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9237 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9238 Trailer Lamps: Pinpoint Tests Test X: The Trailer Lamps Are Inoperative - All PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - ALL X1 X1 Continued Normal Operation The trailer tow connectors receive ground through circuit RAT08 (WH) for all of the trailer lamps. Possible Causes - Circuit RAT08 (WH) open - Trailer Test Y: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER TURN/STOPLAMP Y1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9239 Y1-Y2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9240 Y3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9241 Y4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9242 Y5 Normal Operation The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (OG). The battery junction box (BJB) fuse 34 (25A) supplies voltage to both trailer tow turn relays. The trailer tow turn/stop relay coils are grounded through circuit GD123 (BK/GY). Possible Causes - Fuse - Circuit CAT06 (YE) open - Circuit CAT09 (OG) open - Circuit CLS18 (GY/BN) open - Circuit CLS19 (VT/OG) open - Circuit GD123 (BK/GY) open - BJB - Trailer tow turn relay - Trailer Test Z: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9243 Z1-Z3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9244 Z3-Z4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9245 Z4 Continued Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9246 Z5 Normal Operation The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is grounded through circuit GD123 (BK/GY). The battery junction box (BJB) supplies voltage to the trailer tow parking lamp relay switch side through circuit SBB12 (GN/RD). When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). Possible Causes - Fuse - Circuit CAT11 (BN) open - Circuit CLS30 (VT/WH) open - Circuit GD123 (BK/GY) open - Circuit SBB12 (GN/RD) open - Trailer tow parking lamp relay - Trailer Tests AA: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS AA1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9247 AA1-AA2 Normal Operation The battery junction box (BJB) fuse 63 (15A) receives voltage from circuit CLS10 (GY/BN) when the vehicle reversing lamps are illuminated. The voltage is then routed to the trailer tow connector through circuit CAT16 (GY/BN). Possible Causes - Fuse - Circuit CAT16 (GY/BN) open - Circuit CLS10 (GY/BN) open - Trailer Tests AB: The Trailer Lamps Are On Continuously PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9248 AB1-AB2 Normal Operation - Trailer Tow Turn/Stoplamp The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed the trailer tow connector through circuit CAT06 YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (OG). Normal Operation - Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). Possible Causes - Circuit CAT06 (YE) short to voltage - Circuit CAT09 (OG) short to voltage - Circuit CAT11 (BN) short to voltage - Trailer tow relay - Trailer Tests AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9249 AC1-AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9250 AC3-AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9251 AC4-AC5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9252 AC5-AC6 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9253 AC6-AC8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9254 AC8-AC10 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9255 AC10-AC11 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 42 (10A) through circuit CAT23 (GY/YE) when the ignition switch is in the RUN position. Ground for the trailer battery charge relay coil is supplied through circuit GD123 (BK/GY). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay switch side through circuit SSB13 (GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow connector through circuit CAT14 (OG). Possible Causes - Fuse - Circuit CAT14 (OG) open or short to voltage - Circuit CAT23 (GY/YE) open or short to voltage - Circuit GD123 (BK/GY) open - Circuit SSB13 (GY/RD) open - Trailer battery charge relay - Trailer - SJB Tests AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9256 AD1-AD2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9257 AD2-AD4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9258 AD5-AD7 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9259 AD8-AD9 Normal Operation The trailer brake control module is provided voltage at all times by the battery junction box (BJB) fuse 5 (40A) through circuit SBB05 (GY/RD). Ground for the trailer brake control module is provided through circuit GD138 (BK/WH). The trailer brake control module receives voltage from the stoplamp switch through circuit CLS17 (YE/GY) when the brake pedal is applied. When requested, the trailer brake control module sends voltage to the trailer tow connector through circuit CAT19 (BU). Circuit CLS30 (VT/WH) supplies voltage to the trailer brake control module when the parking lamps are on. Possible Causes - Fuse - Circuit CAT19 (BU) open, short to ground or voltage - Circuit CLS17 (YE/GY) open - Circuit CLS30 (VT/WH) open - Circuit GD138 (BK/WH) open - Circuit SBB05 (GY/RD) open - Trailer brake control module - Trailer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 9260 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 9265 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 9266 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9269 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9270 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9271 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9272 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9273 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9274 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9275 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9276 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9281 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9282 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9285 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9286 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9287 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9288 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9289 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9290 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9291 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9292 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 orientation. 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9314 Trailer Connector: Connector Views C4098 C4099 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9315 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 (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9316 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9317 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 (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation Body Control Module: Service and Repair Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the Original Module is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation Using the Integrated Diagnostic System IDS) When the Original Module is NOT Available NOTE: Following module installation, some modules require a separate learning procedure carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press check mark. 8. If the data is not available, the IDS displays screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Programmable Module Installation > Page 9325 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. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 2 bolts and the retractable running board module assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left C3185 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left > Page 9334 C3186 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures Front Bumper Cover / Fascia: Procedures TAB REPAIR - BUMPER 1. NOTE: - Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the following steps. - The following steps are to be used as a guideline. Depending on what brand of adhesives, patch material etc., are used, procedures may vary slightly. Remove the affected bumper. Refer to Bumpers. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area. - Immediately apply the plastic repair material to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Refer to Bumpers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 9341 Front Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - FRONT Exploded View Removal and Installation 1. Remove the 3 lower air deflector pin-type retainers. - Position the air deflector aside. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 9342 2. Remove the 2 front bumper cover lower pin-type retainers. 3. Remove the 4 LH and RH front fender splash shield screws. 4. Remove the 4 LH and RH front bumper cover-to-fender bolts. - To install, tighten to 11 Nm (8 lb-ft). 5. If equipped, disconnect the LH and RH fog lamp electrical connectors. 6. Remove the upper air deflector. - Remove the 10 pin-type retainers. NOTE: Right side shown, left side similar. 7. Remove the 2 upper pin-type retainers for the lower air deflector. 8. Remove the 4 grille-to-radiator support bolts. 9. Remove the front bumper cover. 10. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair BUMPER - FRONT Exploded View Removal and Installation 1. Remove the front bumper cover. 2. Remove the front bumper. - Remove the 6 nuts. - To install, tighten to 90 Nm (66 lb-ft). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures Rear Bumper Cover / Fascia: Procedures TAB REPAIR - BUMPER 1. NOTE: - Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the following steps. - The following steps are to be used as a guideline. Depending on what brand of adhesives, patch material etc., are used, procedures may vary slightly. Remove the affected bumper. Refer to Bumpers. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area. - Immediately apply the plastic repair material to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Refer to Bumpers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 9351 Rear Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - REAR Exploded View Removal and Installation 1. Remove the 4 LH and RH rear fender splash shield screws. NOTE: Left side shown, right side similar. 2. Remove the 4 LH and RH inner bumper cover nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 9352 3. If equipped, disconnect the reverse parking aid electrical connector. 4. Remove the 2 rear bumper cover lower pin-type retainers. 5. Remove the rear bumper cover. - Remove the 2 rear bumper cover pin-type retainers and the 3 rear bumper cover bolts. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. To install, reverse the removal procedure. 6. If necessary, adjust the windshield wiper arms. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR FRONT DOOR HANDLE Removal and Installation NOTE: The front door window glass must be completely raised. 1. Remove the front door trim panel. - Position the water shield aside. 2. Open the clip and disconnect the exterior door handle actuating rod. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9364 3. If equipped, disconnect the door lock cylinder actuating rod from the lock cylinder. 4. NOTE: Push the exterior door handle out from the bottom surface of the handle. Remove the 2 nuts and the exterior front door handle. To install, tighten to 9 Nm (80 lb-in). 5. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9373 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9374 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9375 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9376 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9377 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9378 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9379 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Front Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Front Door Interior Handle: Recalls Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9389 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9390 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9391 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9392 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9393 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9394 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9395 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Front Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Front Door Interior Handle: By Symptom Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9405 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9406 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9407 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9408 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9409 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9410 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9411 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Front Door Interior Handle: All Technical Service Bulletins Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Page 9416 Front Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE Removal and Installation 1. Remove the front or rear door trim panel. 2. Release the door handle retaining clip and position the interior door handle aside. 3. Release the interior door handle actuating cable from the interior door handle. 4. NOTE: Make sure the interior door handle spring is realigned before installation of the door handle. Check for normal operation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 9421 7. Install and adjust the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9422 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 the door striker. 2. Loosen the front door hinge-to-front door bolts enough to allow movement of the door. 3. Adjust the front door. 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair FRONT DOOR LATCH Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the front door trim panel. - Position the water shield aside. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 9426 2. For the LH door, disconnect the door lock cylinder actuating lock rod from the lock cylinder. 3. Open the clip and disconnect the exterior door handle actuating rod. 4. Disconnect the manual actuating lock rod from the door latch. 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 electrical connectors. - Separate the door harness from the door latch. 7. Release the interior door handle actuating cable and remove the front door latch. 1 Position the cable cover aside. 2 Release the conduit and the interior door handle actuating cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 9427 8. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair DOOR CHECK ARM Left and right sides 1. Remove the lower cowl trim panel. - Remove the door scuff plate. Left side 2. Remove the parking brake control assembly and position aside. Left and right sides 3. Remove the lower cowl panel weather shield. 4. Remove the 2 door check arm-to-door bolts. 5. NOTE: Left side shown, right side similar. Remove the 2 door check arm nuts. 6. Remove the door check arm from the opening in the lower cowl panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair > Page 9431 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair DOOR TRIM PANEL - FRONT Removal and Installation NOTE: Left front door shown, right front door similar. 1. Remove the door handle screw cover. - Use the service notch. 2. Remove the door handle screw. 3. Remove the front door trim panel finish cover. 4. Remove the 2 door trim panel screws. 5. Remove the door trim panel screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 9435 6. Remove the 2 lower door trim panel screws. 7. Disengage the sail panel clip. 8. 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 front door trim panel. Disconnect the electrical connectors. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area Front Door Weatherstrip: Customer Interest Body - Wind Noise From Front Door B-Pillar Area TSB 07-13-4 07/09/07 WIND NOISE AROUND FRONT DOORS - BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-8-6 to clarify vehicle build date. ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience wind noise around the exterior driver and/or passenger doors. This may be most noticeable near the b-pillar area of the door. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE VEHICLE IS BUILT AFTER 12/6/2006, THIS TSB DOES NOT APPLY. PROCEED WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS, REFER TO WORKSHOP MANUAL (WSM), SECTION 100-04. 1. Check the build date of the vehicle. a. If the build date of the vehicle is before 12/1/2006, continue to Step 2. b. If the build date of the vehicle is between 12/1/06 and 12/6/06, continue to Step 3. 2. Verify that the glass run inserts at the b-pillar corner are still in the correct position. (Figure 1) a. First roll down the window and peel back the inner flocked sealing lip in the b-pillar corner. b. There will be two inserts located in the corner. They should both be touching in the corner and at a 90 degree angle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 9444 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 9445 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area Front Door Weatherstrip: All Technical Service Bulletins Body - Wind Noise From Front Door B-Pillar Area TSB 07-13-4 07/09/07 WIND NOISE AROUND FRONT DOORS - BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-8-6 to clarify vehicle build date. ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience wind noise around the exterior driver and/or passenger doors. This may be most noticeable near the b-pillar area of the door. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE VEHICLE IS BUILT AFTER 12/6/2006, THIS TSB DOES NOT APPLY. PROCEED WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS, REFER TO WORKSHOP MANUAL (WSM), SECTION 100-04. 1. Check the build date of the vehicle. a. If the build date of the vehicle is before 12/1/2006, continue to Step 2. b. If the build date of the vehicle is between 12/1/06 and 12/6/06, continue to Step 3. 2. Verify that the glass run inserts at the b-pillar corner are still in the correct position. (Figure 1) a. First roll down the window and peel back the inner flocked sealing lip in the b-pillar corner. b. There will be two inserts located in the corner. They should both be touching in the corner and at a 90 degree angle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 9451 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 9452 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-FRONT Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9457 Exploded View 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR-FRONT DOOR Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 9461 Exploded View Removal and Installation NOTE: For Navigator, the LF/RF door power window regulator motor must be reinitialized whenever the LF/RF motor is removed from the vehicle. 1. Remove the front door trim panel. 2. Position the front door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator assembly to hold the window regulator assembly drum in place. Remove the bolts and the front door window regulator motor. 1 Disconnect the electrical connector. 2 Remove the bolts. To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - For Navigator, reinitialize the LF/RF window regulator motor. - Cycle the window glass to make sure the gears engage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9465 Exploded View Removal and Installation NOTE: For Navigator, the LF/RF door power window regulator motor must be reinitialized whenever the LF/RF window regulator is removed from the vehicle. 1. Remove the front door trim panel. 2. Unlock the tabs and remove the window control switch from the door trim panel. 3. Remove the screws and the front door speaker. - Disconnect the electrical connector. 4. Remove the front door weathershield. 5. Re-connect the electrical connectors to the window control switch. 6. Lower the window glass to access the 2 window glass clamp bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9466 7. Loosen the window glass clamp bolts. - To install, raise the window glass until it stalls in the UP position. Tighten the window glass clamp bolts to 11 Nm (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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9467 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. 14. For Navigator, reinitialize the LF/RF window regulator motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR REAR DOOR HANDLE Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the rear door trim panel. - Position the water shield aside. 2. Remove and discard the 3 bolts and position the rear door latch aside. - To install, tighten to 9 Nm (80 lb-in). 3. Open the clip and disconnect the exterior door handle actuating rod. 4. Remove the 2 nuts and the exterior rear door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 > Page 9473 - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9482 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9483 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9484 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9485 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9486 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9487 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9488 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Recalls for Rear Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Rear Door Interior Handle: Recalls Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9498 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9499 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9500 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9501 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9502 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9503 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9504 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > By Symptom for Rear Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Rear Door Interior Handle: By Symptom Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement Technical Service Bulletin # 08S03 Date: 080206 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated by February 6, 2008. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by February 6, 2008. Owner names and addresses will be available by February 21, 2008. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9514 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 If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9515 PARTS REQUIREMENTS / ORDERING INFORMATION Parts are currently available to service 100% of the affected vehicle population. Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN 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. Attachment III - Technical Information OVERVIEW This program involves replacing the front and rear interior side door handle springs. SERVICE PROCEDURE 1. Remove the interior side door handle bezel screw cover, screw and bezel. See Figure 1. 2. NOTICE: Use caution not to damage the plastic retaining clip when removing the interior side door handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9516 Remove the interior side door handle by using a flat-blade screwdriver to pry upon the plastic retaining clip while pulling the interior side door handle out of the retainer. See Figure 2. 3. Disconnect the interior side door handle cable from the interior side door handle. See Figure 3. 4. NOTICE: When removing the interior side door handle pin, hold the interior side door handle with extreme care so it is not scratched or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9517 Remove the interior side door handle spring pin and spring. See Figure 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9518 5. NOTE: The interior side door handle spring retainer may be cracked or missing. See Figure 6 for the location of the spring retainer. The new re-designed spring has a longer leg and does not need the retainer to function. The door handle does not need to be replaced, even if the spring retainer is damaged. See Figure 5 for example of re-designed spring. Position the new interior side door handle spring (LH is green, RH is gray) into the interior side door handle and install the interior side door handle spring pin. The new spring can be installed into the retainer even if the retainer is damaged or broken. See Figure 6 for example of correct assembly. 6. Install the interior side door handle cable to the interior side door handle. See Figure 3. 7. Install the interior side door handle into the retaining clip. Make sure the handle is seated correctly in the retainer. See Figure 3. 8. Install the door handle bezel, screw and screw cover. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9519 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 08S03 > Feb > 08 > Recall - Inner Door Handle Spring Replacement > Page 9520 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > NHTSA08V058000 > Feb > 08 > Recall 08V058000: Inner Door Handle Spring Replacement Rear Door Interior Handle: All Technical Service Bulletins Recall 08V058000: Inner Door Handle Spring Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2007-2008 Lincoln/Navigator 2007-2008 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: February 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V058000 NHTSA ACTION NUMBER: N/A COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 123632 SUMMARY: Ford is recalling 123,632 M/Y 2007-2008 Expedition and Lincoln Navigator vehicles. The door handle housing embossment retaining the bottom of the interior door handle spring on all side doors may fracture during normal customer usage. This can result in insufficient spring force to return the handle to the fully closed position. The handle may be loose causing a rattle or noise and the handle may not return to the fully closed position. This condition may also provide a delayed resistance when actuating the handle prior to opening the door. CONSEQUENCE: In the event of a side impact crash, the interior door handle may cause the door latch to open increasing the risk of injury to a vehicle occupant. REMEDY: Dealers will replace the interior handle spring on all side doors. The recall is expected to begin during February 2008. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 08S03. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Page 9525 Rear Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE Removal and Installation 1. Remove the front or rear door trim panel. 2. Release the door handle retaining clip and position the interior door handle aside. 3. Release the interior door handle actuating cable from the interior door handle. 4. NOTE: Make sure the interior door handle spring is realigned before installation of the door handle. Check for normal operation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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-REAR DOOR, FORE, AFT AND TILT 1. Position the front seat in the full forward position. 2. Remove the 2 door striker bolts and the door striker. 3. Remove the front seat belt retractor. 4. Remove the B-pillar weathershield. 5. Loosen the rear door hinge-to-B-pillar nuts enough to allow movement of the rear door. 6. Adjust the rear door. 7. Tighten the rear door hinge-to-B-pillar nuts to 30 Nm (22 lb-ft). 8. Install the B-pillar weathershield. 9. Install the front seat belt retractor. 10. Install and adjust the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9530 Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear, In, Out, Up and Down HINGE ADJUSTMENT-REAR DOOR, IN, OUT, UP AND DOWN 1. Remove the 2 door striker bolts and the door striker. 2. Loosen the rear door hinge-to-rear door bolts enough to allow movement of the door. 3. Adjust the rear door. 4. Tighten the rear door hinge-to-rear 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair REAR DOOR LATCH Removal and Installation NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. - Position the water shield aside. 2. Remove and discard the 3 bolts and position the rear door latch aside. - To install, tighten to 9 Nm (80 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 9534 3. Open the clip and disconnect the exterior door handle actuating rod. 4. Disconnect the electrical connectors. 5. Release the interior door handle actuating cable and remove the rear door latch. 1 Position the cable cover aside. 2 Release the conduit and the interior door handle actuating cable. 6. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair DOOR TRIM PANEL - REAR Removal and Installation NOTE: Left rear door shown, right rear door similar. 1. Remove the door handle screw cover. - Use the service notch. 2. Remove the door handle screw. 3. Remove the rear door trim panel finish cover. 4. Remove the 2 door trim panel screws. 5. Remove the door trim panel screw. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 9538 6. Remove the 2 lower door trim panel screws. 7. 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 rear door trim panel. If equipped, disconnect the electrical connectors. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-REAR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9543 Part 2 Exploded View 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR-REAR DOOR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Page 9547 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel 2. Position the rear door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window regulator assembly to hold the window regulator assembly drum in place. Remove the rear door window regulator motor. 1 Disconnect the electrical connector. 2 Remove the bolts. To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9551 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel 2. NOTE: LF shown, LR and RR are similar. Unlock the tabs and remove the window control switch from the door trim panel. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9552 4. Remove the rear door weathershield. 5. Connect the window control switch. 6. Lower the window glass to access the window glass clamp bolts. 7. Disconnect the window control switch. 8. Loosen the window glass clamp bolts and remove the rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 9. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the front door frame. 10. Disconnect the rear door window regulator electrical connectors. 11. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9553 12. Remove the rear door window regulator assembly. - Remove the bolts. To install, tighten to 11 Nm (8 lb-ft). 13. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair HOOD LATCH Removal and Installation 1. Remove the 10 pin-type retainers and the upper radiator sight shield. 2. Remove the 2 bolts and the hood latch. - To install, tighten to 35 Nm (26 lb-ft). 3. Release the hood latch cable from the hood latch. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 9558 - 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair HOOD LATCH RELEASE HANDLE Removal and Installation 1. Remove the hood latch. - Note the routing of the hood release cable. 2. Remove the 3 screws and the steering column cover. 3. Remove the 2 screws and the hood latch release handle. 4. Release the cable guides and pull the cable through the cowl panel. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair WINDOW GLASS-LIFTGATE Material Material Removal and Installation Window glass assembly 1. Remove the rear window wiper motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9566 2. Disconnect the rear window defrost electrical connectors. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9567 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 (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 9576 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 9582 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9583 Power Trunk / Liftgate Control Module: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9584 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9585 Power Trunk / Liftgate Control Module: Diagrams C4174A C4174B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9586 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the bolt. To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations View 151-41 (Liftgate - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9590 C4040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-41 (Liftgate - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch C4340 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 9596 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair Power Trunk / Liftgate Hazard Sensor: Service and Repair PINCH STRIP SWITCH Removal and Installation NOTE: Left side shown, right side similar. 1. Remove brake light. - Remove the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Page 9600 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1 Remove the pin-type retainers. 2 Remove the grommet and route the harness out of the vehicle. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 28 Nm (21 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair LIFTGATE RELEASE HANDLE Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 9607 Navigator Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 9608 Removal and Installation All vehicles 1. Remove the liftgate trim panel. - Position the water shield aside. Expedition 2. Remove the 2 nuts and the liftgate release handle. - Disconnect the electrical connector. - To install, tighten to 6 Nm (53 lb-in). Navigator 3. Remove the 6 nuts and the license plate housing. - Disconnect the electrical connector. - To install, tighten to 5 Nm (44 lb-in). 4. Remove the 2 nuts and the liftgate release handle. - Disconnect the electrical connector. - To install, tighten to 9 Nm (80 lb-in). All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-3 > Sep > 08 > Body - Power Liftgate Grunt/Groan/Squeal Noise Trunk / Liftgate Hydraulic Control Unit: Customer Interest Body - Power Liftgate Grunt/Groan/Squeal Noise TSB 08-18-3 09/15/08 POWER LIFTGATE - GRUNT/GROAN/SQUEAL NOISE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with power liftgates may exhibit a grunt/groan/squeal noise when powered open/close. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disconnect the power liftgate actuator / lift rod assembly from the liftgate and body, then manually open and close liftgate. 2. If the noise is gone, replace power liftgate actuator / lift rod and initialize the power liftgate. Reference Workshop Manual (WSM), Section 501-03. 3. If the noise does not go away, reconnect the liftgate actuator rod and initialize the power liftgate. See Power Liftgate Initialization procedure in WSM, Section 501-03, under general procedures. Follow normal WSM, Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081803A 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace The Power Lift Rod, Includes Time To Remove And Install Interior Trim Panels And Perform Initialization Procedure. (Do Not Use With 14350A, 31012A) DEALER CODING CONDITION BASIC PART NO. CODE 78431 A78 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-3 > Sep > 08 > Body - Power Liftgate Grunt/Groan/Squeal Noise Trunk / Liftgate Hydraulic Control Unit: All Technical Service Bulletins Body - Power Liftgate Grunt/Groan/Squeal Noise TSB 08-18-3 09/15/08 POWER LIFTGATE - GRUNT/GROAN/SQUEAL NOISE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with power liftgates may exhibit a grunt/groan/squeal noise when powered open/close. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disconnect the power liftgate actuator / lift rod assembly from the liftgate and body, then manually open and close liftgate. 2. If the noise is gone, replace power liftgate actuator / lift rod and initialize the power liftgate. Reference Workshop Manual (WSM), Section 501-03. 3. If the noise does not go away, reconnect the liftgate actuator rod and initialize the power liftgate. See Power Liftgate Initialization procedure in WSM, Section 501-03, under general procedures. Follow normal WSM, Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081803A 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace The Power Lift Rod, Includes Time To Remove And Install Interior Trim Panels And Perform Initialization Procedure. (Do Not Use With 14350A, 31012A) DEALER CODING CONDITION BASIC PART NO. CODE 78431 A78 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Control Unit: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Accessory Control Display: All Technical Service Bulletins Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Control Unit: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 9627 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Control Unit: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 9628 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Control Unit: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 9634 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Control Unit > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Control Unit: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 9635 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-3 > Sep > 08 > Body - Power Liftgate Grunt/Groan/Squeal Noise Trunk / Liftgate Hydraulic Cylinder: Customer Interest Body - Power Liftgate Grunt/Groan/Squeal Noise TSB 08-18-3 09/15/08 POWER LIFTGATE - GRUNT/GROAN/SQUEAL NOISE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with power liftgates may exhibit a grunt/groan/squeal noise when powered open/close. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disconnect the power liftgate actuator / lift rod assembly from the liftgate and body, then manually open and close liftgate. 2. If the noise is gone, replace power liftgate actuator / lift rod and initialize the power liftgate. Reference Workshop Manual (WSM), Section 501-03. 3. If the noise does not go away, reconnect the liftgate actuator rod and initialize the power liftgate. See Power Liftgate Initialization procedure in WSM, Section 501-03, under general procedures. Follow normal WSM, Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081803A 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace The Power Lift Rod, Includes Time To Remove And Install Interior Trim Panels And Perform Initialization Procedure. (Do Not Use With 14350A, 31012A) DEALER CODING CONDITION BASIC PART NO. CODE 78431 A78 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-3 > Sep > 08 > Body - Power Liftgate Grunt/Groan/Squeal Noise Trunk / Liftgate Hydraulic Cylinder: All Technical Service Bulletins Body - Power Liftgate Grunt/Groan/Squeal Noise TSB 08-18-3 09/15/08 POWER LIFTGATE - GRUNT/GROAN/SQUEAL NOISE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with power liftgates may exhibit a grunt/groan/squeal noise when powered open/close. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Disconnect the power liftgate actuator / lift rod assembly from the liftgate and body, then manually open and close liftgate. 2. If the noise is gone, replace power liftgate actuator / lift rod and initialize the power liftgate. Reference Workshop Manual (WSM), Section 501-03. 3. If the noise does not go away, reconnect the liftgate actuator rod and initialize the power liftgate. See Power Liftgate Initialization procedure in WSM, Section 501-03, under general procedures. Follow normal WSM, Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081803A 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace The Power Lift Rod, Includes Time To Remove And Install Interior Trim Panels And Perform Initialization Procedure. (Do Not Use With 14350A, 31012A) DEALER CODING CONDITION BASIC PART NO. CODE 78431 A78 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure Hose/Line HVAC: All Technical Service Bulletins A/C - Compressor Failure TSB 07-18-3 09/17/07 A/C COMPRESSOR FAILURE FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/18/2007 may have A/C system filters (integral to the receiver/dryer desiccant cartridge) that fail to filter the system. If the unit has had a compressor failure that has sent debris into the system, the filter will not stop the debris from contaminating the entire system. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed. WITH ROTUNDA A/C FLUSH AND PURGE MACHINE: 1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures. 2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine. 3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor. 4. Remove and replace the A/C discharge and muffler line from the system. 5. Remove the condenser from the vehicle. 6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present. 8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine. 9. Remove the original plug and snap-ring and discard. 10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the Front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9654 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9655 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9656 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9662 14. Remove the rear TXV and discard if equipped. 15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes. 16. Install a new rear TXV. 17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle. 18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes, followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator. 19. Reconnect all A/C fittings. 20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated). 21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes. A/C FLUSH AND PURGE - WITHOUT ROTUNDA MACHINE: 1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures. 2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle. 3. Remove and replace the discharge line. 4. Remove and replace the front TXV and rear TXV if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place. 5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard. 6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser. 7. Remove the right front headlamp assembly per the WSM, Section 417-01. 8. Disconnect the lower (liquid) line connection to the condenser. 9. Pull the liquid line slightly forward so it will clear the condenser. 10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser. 11. Charge the system with the correct amount of R134a. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C 12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature. 13. Recover the R134a in the system. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9663 14. Remove the condenser. 15. Remove the original desiccant cartridge plug and 0-rings and discard. 16. Install a new desiccant cartridge, plug w/ 0-rings, snap ring, and cap. NOTE IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY. 17. Install the condenser 18. Install the headlamp assembly per WSM, Section 417-01. 19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM. ^ 22 oz. - Front A/C ^ 33 oz. - With Auxiliary A/C NOTE COMPONENTS OF THE ROTUNDA 1/2" DSL AC FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hydraulic Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Hydraulic Cylinder: > 07-18-3 > Sep > 07 > A/C - Compressor Failure > Page 9664 MTO71803 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19C836 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair LIFTGATE TRIM PANEL All vehicles 1. Open the liftgate and remove the scrivets. Vehicles with power liftgate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Page 9668 2. Remove the power liftgate rod-to-liftgate cover and nut. - To install, tighten to 11 Nm (8 lb-ft). 3. Remove the power liftgate rod. All vehicles 4. 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. 5. Remove the assist handle. 1 Remove the screws. 2 Remove the assist handle. 6. 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. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams > Liftgate Latch C457 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams > Liftgate Latch > Page 9673 C4339 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch LIFTGATE LATCH Manual Liftgate Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9676 Power Liftgate Removal and Installation 1. Remove the liftgate trim panel. - Position the water shield aside. 2. Remove and discard the 3 bolts (4 bolts if equipped with a power liftgate) and the liftgate latch. - Disconnect the electrical connector. - To install, tighten to 12 Nm (9 lb-ft). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9677 Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Window LIFTGATE LATCH - WINDOW Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 2 screws and the liftgate window latch. - Disconnect the electrical connector. - To install, tighten to 8 Nm (71 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations Trunk / Liftgate Motor: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 9681 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 9682 C4332 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Motor Trunk / Liftgate Motor: Service and Repair Power Liftgate Motor POWER LIFTGATE MOTOR Removal and Installation 1. Remove the power liftgate rod assembly. 2. Disconnect the power liftgate motor electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Motor > Page 9685 3. Remove the power liftgate retaining fasteners and the power liftgate motor assembly. - To install, tighten to 11 Nm (8 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Motor > Page 9686 Trunk / Liftgate Motor: Service and Repair Power Liftgate Rod POWER LIFTGATE ROD Material Material Removal and Installation 1. Remove the LH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Motor > Page 9687 2. Unclip the power liftgate rod from the motor assembly. - Squeeze the clip as shown to release and position upward on the rod assembly. 3. Remove the cover and the power liftgate rod-to-liftgate retaining nut. - To install, apply Threadlock 262 to the threads of fastener and tighten to 11 Nm (8 lb-ft). 4. Remove the power liftgate rod-to-bracket bolt and the power liftgate rod assembly. - To install, tighten to 30 Nm (22 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 9692 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 9693 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch C4333 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 9696 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. To install, reverse the removal procedure. 6. If necessary, adjust the windshield wiper arms. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 9706 Part 2 Exploded View Vehicles with power running boards 1. Lower the running board. All vehicles 2. Remove the lower pin-type retainer from the fender. 3. Remove the 8 fender splash shield screws. 4. Remove the 2 inner pin-type retainers from the fender splash shield. 5. Remove the fender splash shield. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation DESCRIPTION AND OPERATION Frame and Body Mounting The frame is made up of 2 steel boxed side rails and crossmembers, which are welded to the 2 side rails. The transmission crossmember is bolted to the side rails. The side welded rails and crossmembers are not replaced separately. The service kits available for the frame are the following: RH front horn replacement kit - LH front horn replacement kit - Front bumper bracket replacement kit - 1B crossmember replacement kit - Transmission crossmember replacement kit Refer to the instructions included in the kits for installation instructions. Frame Mounted Heat Shields All frame mounted heat shields, except the spare tire heat shield, are tightened to 20 Nm (15 lb-ft). The spare tire heat shield is tightened to 25 Nm (18 lb-ft). Frame Components Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9711 Frame Components Spare Tire Winch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9712 Spare Tire Winch Skid Plates Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9713 Skid Plates Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Removal and Installation No. 1 Body Support Mount N0. 1 Body Support Mount 1. Remove the body mount bolt. - To install, tighten to 103 Nm (76 lb-ft). 2. Loosen the remaining body mount bolts. 3. Raise the vehicle body enough to remove the body mount bolts and body mount. - To install, tighten to 55 Nm (41 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9716 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 (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9717 Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 and Number 3 Body Support - Number 2 and Number 3 Removal and Installation No. 2 Body Support Mount NOTE: No. 2 body mount is shown, body mount No. 3 similar. N0. 2 Body Support Mount 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). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9718 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 (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9719 Body / Frame Mount Bushing: Service and Repair Body Support - Number 4 Body Support - Number 4 Removal and Installation No. 4 Body Mount N0. 4 Body Support Mount 1. Remove the liftgate scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9720 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 (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9721 Body / Frame Mount Bushing: Service and Repair Body Support - Front End Sheet Metal Body Support - Front End Sheet Metal Removal and Installation Front End Sheet Metal Body Mount Front End Sheet Metal Body Mount Upper and lower body mount Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9722 1. Remove the lower front end sheet metal body mount. 1 Remove the lower front end sheet metal body mount bolt. 2 Remove the lower front end sheet metal 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 front end sheet metal 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 (2007)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember - Exploded View Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate fasteners and skid plate. 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Page 9727 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: - Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. - The crossmember nuts are installed on the crossmember bolts facing the front of the vehicle. Remove the 4 transmission crossmember bolts (2 each side) and the transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Trailer Hitch Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 9731 WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a rear end collision. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the trailer hitch rear bumper cover trim panel, if equipped. 3. Remove the 4 trailer lighting plug cover bolts. 4. Remove the trailer lighting plug. - Position the plug away from the trailer hitch. - Disconnect the electrical connector. - Remove the trailer lighting plug. 5. Remove the electrical connector from the trailer hitch and unclip the harness from the retainers on the frame. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 9732 6. Remove the 4 trailer hitch side mounting bolts (2 each side). - To install, tighten to 175 Nm (129 lb-ft). 7. Remove the 4 trailer hitch lower mounting bolts (2 each side) and remove the trailer hitch. - To install, tighten to 275 Nm (203 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 9733 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9738 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9739 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9742 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9743 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9744 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9745 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9746 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9747 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9748 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9749 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 9753 Navigator Removal and Installation All vehicles 1. Remove the front bumper cover. Expedition only 2. Remove the 4 bumper assembly-to-grille bracket retainer nuts and the bumper assembly-to-grille bracket. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 9754 3. NOTE: Expedition shown, Navigator similar. Remove the clips and remove the front grille. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9765 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9766 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9767 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9768 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9769 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9770 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9771 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9772 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9773 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9774 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9775 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9776 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9777 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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. Open the glove compartment. 2. CAUTION: Forcing the glove compartment past the stops will damage the dampener. If equipped, disconnect the dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 9781 3. Release the stops. 4. Remove the 3 glove compartment screws and the glove compartment. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Headliner: Customer Interest Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 9790 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Headliner: All Technical Service Bulletins Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 9796 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 9797 Headliner: Service and Repair HEADLINER 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 (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 9798 3. If equipped, remove the roof opening panel trim. 4. Remove the LH and RH A-pillar trim panels. 5. Remove the 2 wiring harness pin-type retainers from the A-pillar. 6. Open and fully lower the glove compartment. - Release the glove compartment tabs. 7. If equipped, disconnect the satellite radio antenna. 8. Remove the pin-type retainer and disconnect the electronic compass/auto-dimming rearview mirror electrical connector. 9. If equipped, separate the satellite antenna cable from the wiring harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 9799 10. If equipped, remove the electronic compass sensor. 11. If equipped, disconnect the auto-dimming mirror electrical connector. 12. Remove the LH and RH sun visor clips. - Remove the 8 screws. - Remove the sun visors and visor clips. If equipped, disconnect the electrical connectors. 13. If equipped, remove the overhead console. - Disconnect the electrical connectors. 14. If equipped, remove the DVD player. 15. Remove the LH and RH B-pillar trim panels. 16. Remove the LH and RH C-pillar trim panels. 17. Remove the LH and RH D-pillar trim panels. 18. Disconnect the rear electrical connector. Vehicles with safety canopies 19. Remove the 4 garment hangers. - Open the access panel. - Remove the garment hanger screws. Vehicles without safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 9800 20. CAUTION: To prevent damage to the garment hanger retainer, use a 3/16-inch flat-blade screwdriver for this step. NOTE: The garment hanger is shown without the roof sheet metal to show the metal retainer clip. The metal retainer clip will remain engaged in the sheet metal after the garment hanger is removed. Remove the 2 garment hangers. 1 Open the access cover. 2 Insert the flat-blade screwdriver fully into the garment slot. 3 Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip. Remove the plastic garment hanger. All vehicles 21. Remove the center pin-type retainers. 22. Remove the rear pin-type retainers. Vehicles with rear climate control 23. Tilt the headliner to release the vent duct. All vehicles 24. Remove the headliner. 25. To install, reverse the removal procedure. - Transfer parts as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9805 Part 2 Exploded View Removal and Installation 1. Remove the 2 front assist handle bolt covers. 2. Remove the 2 assist handle 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 (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9806 Trim Panel: Service and Repair B-Pillar Trim Panel B-PILLAR TRIM PANEL Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9807 Part 2 Exploded View Removal and Installation Upper and lower 1. Move the front seat to the full forward position. 2. NOTE: - Position the shoulder safety belt guide to the lowest position. - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide cover. Detach the top of the shoulder safety belt guide cover. - Rotate the shoulder safety belt guide cover 90 degrees and remove from the safety belt guide bolt. 3. Remove the shoulder safety belt guide. - Remove the shoulder safety belt guide bolt. To install, tighten to 40 Nm (30 lb-ft). - Remove the shoulder safety belt guide. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9808 4. 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 5. Remove the front and rear door scuff plates. 6. Position the lower B-pillar trim panel aside. 7. Remove the front safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 8. Feed the safety belt through the lower B-pillar trim panel and remove. Upper and lower 9. To install, reverse the removal procedure. - When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9809 Trim Panel: Service and Repair C-Pillar Trim Panel C-PILLAR TRIM PANEL Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9810 Part 2 Exploded View Removal and Installation All vehicles 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety belt cover up. 2 Remove the safety belt guide bolt. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Detach the safety belt holder pin-type retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9811 3. Remove the C-pillar trim panel fastener cover. Expedition EL/Navigator L only 4. Remove the C-pillar trim panel nut. - To install, tighten to 8 Nm (71 lb-in). All vehicles except Expedition EL 5. Remove the C-pillar trim panel bolt. - To install, tighten to 8 Nm (71 lb-in). All vehicles 6. Remove the C-pillar trim panel. - Remove the C-pillar trim panel by pulling outward to release the retainers. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9812 Trim Panel: Service and Repair D-Pillar Trim Panel D-PILLAR TRIM PANEL Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9813 Part 2 Exploded View Removal and Installation All vehicles except Expedition EL/Navigator L NOTE: Right side with power vent windows shown, all others similar. 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety guide cover up. 2 Remove the shoulder safety belt guide bolt. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. All vehicles 2. Remove rear upper headliner trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9814 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. If equipped, disconnect the speaker electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9815 Trim Panel: Service and Repair Quarter Trim Panel QUARTER TRIM PANEL All vehicles 1. Remove the C-pillar trim panel. 2. Remove the D-pillar trim panel. 3. Remove the liftgate scuff plate by pulling upward. All vehicles except Expedition EL/Navigator L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9816 4. Remove the rear floor cargo space trim panel. All vehicles 5. Remove the floor jack assembly. Expedition EL/Navigator L 6. Remove the cargo space trim panel. 1 Move the cargo shelf to the upright position. 2 Remove the cargo space trim panel. 7. NOTE: RH cargo shelf bracket shown, LH similar. Remove the 4 cargo shelf bracket bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9817 All vehicles 8. Remove the pin-type retainers and pull back the carpeting. 9. Remove the 2 bolts and the cargo space panel by pulling upward. All vehicles except Expedition EL/Navigator L 10. Remove the third row seat safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 11. Remove the rear quarter trim panel pin-type retainer. Expedition EL/Navigator L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9818 12. Remove the third row seat safety belt anchor and scrivet. - To install, tighten to 40 Nm (30 lb-ft). 13. Remove the rear quarter trim panel bolt. 14. Open the third row seat safety belt guide bolt cover and remove the safety belt guide bolt. - To install, tighten to 40 Nm (30 lb-ft). All vehicles 15. Remove the second row safety belt anchor. - To install, tighten to 40 Nm (30 lb-ft). 16. Remove the rear door scuff plate by pulling upward. 17. Fold the seat back of the third row seat to the full down position. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9819 18. 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, power liftgate switch or the power third row seat switch electrical connector at the rear. 19. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams C500 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 9829 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: Up to 3 codes can be programmed. Once there are 3 programmed codes, any attempt to program additional codes will be unsuccessful. 1. Enter the permanent factory keyless entry keypad code. 2. NOTE: The locks should lock and unlock to indicate programming mode has been entered. 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 codes. 3. Within 5 seconds, enter the new 5-digit keypad code. The doors lock and unlock to confirm the new code is programmed. If the locks do not lock and unlock, the new code programming has not been successful and the procedure must be started from the beginning. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 9830 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior mirror. 2. Remove the front door outer glass weatherstrip. - Disconnect the electrical connector. 3. Release the tabs and remove the keyless entry keypad. - Disconnect the keypad harness retaining clips from the weatherstrip. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming 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 scan tool or by carrying out the following steps. - Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Turn the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the transmitter. If the door locks do not respond for the programmed RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to respond, refer to Locks, Latches and Entry Systems. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9835 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Programming the Autolock Feature Using the Door Lock Control Switch NOTE: - This feature can also be enabled or disabled using the message center switch functions, if equipped. - The autolock feature can be enabled or disabled independently of the auto-unlock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice within 5 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: - This feature can also be enabled or disabled using the message center switch functions, if equipped. - The auto-unlock feature can be enabled or disabled independently of the autolock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position.The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door unlock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9836 Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: - The autolock feature can be enabled or disabled independently of the auto-unlock feature. - The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: - The auto-unlock feature can be enabled or disabled independently of the autolock feature. - The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation Keyless Entry Transmitter: Service and Repair Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Move the seat, rear view mirrors, and adjustable pedals to the desired position. 2. Press the memory set switch SET button. 3. Within 5 seconds, press any button on the remote transmitter (except the PANIC button), and then press the appropriate memory set switch button. 4. Repeat Steps 1-3 for each remote transmitter to be programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation > Page 9839 Keyless Entry Transmitter: Service and Repair Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the memory set switch SET button. 2. Within 5 seconds, press any button on the remote transmitter that is to be deactivated (except the PANIC button), and then press the memory set switch SET button. 3. Repeat Steps 1 and 2 for each remote transmitter to be deactivated from the memory setting. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 9845 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 9846 View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 9847 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 9850 C603 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 9851 C704 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 9852 C804 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9853 Power Door Lock Actuator: Service and Repair DOOR LOCK ACTUATOR Removal and Installation 1. Remove the door latch. 2. Release the locking tab and remove the door lock actuator. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 9858 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 9861 C605 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9862 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9863 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9864 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9870 Memory Positioning Module: Diagrams C341A C341B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9871 C341C C341D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9872 C341E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9879 C3246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair EXTERIOR MIRROR MOTOR Exploded View 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, they must be synchronized. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9886 C527 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9887 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9888 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9889 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9890 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9896 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. DX - Dark Blue Pearl - G2 - Redfire - G3 - Pueblo Gold - G5 - Alloy Gray - JP - Silver Birch Metallic - PG - Dark Amethyst - PV - White Chocolate (tri-coat) - T5 - Dark Copper - UA - Ebony - YZ - Oxford White Interior Trim Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9897 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 - Verona leather, 40/40 captain's chairs - Expedition - 2 - Verona Leather, 40/40 captain's chairs - Expedition - 3 - Verona Leather, 40/40 captain's chairs with accent - Expedition - F - Beck cloth captain's chairs - Expedition - M - Adobe/Beck cloth, 40/60 split bench seat - Expedition - T - Premium/Soho Leather, 40/40 captain's chairs - Navigator Interior Trim Color C - Camel Tan - L - Medium Light Stone - W - Charcoal Black Tape/Paint Stripe Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9898 Tape/Paint Stripe Tape and paint stripe codes do not apply Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9899 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 (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9904 Memory Positioning Module: Diagrams C341A C341B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9905 C341C C341D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9906 C341E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation DRIVER SEAT MODULE - MEMORY SEAT The power driver seat, power outside rear view mirrors, power adjustable pedals and adjustable steering column are controlled by the driver seat module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM is located on the driver seat track. This system allows automatic positioning of the driver seat to 2 programmable positions. The memory seat system consists of the following components: - DSM - Driver memory seat control switch - Memory set switch - Adjustable pedal switch - Power mirror switch - Adjustable steering column switch - Memory seat track assembly (with seat position sensors integral to motors) Horizontal motor (part of seat track) - Front height motor (part of seat track) - Rear height motor (part of seat track) - Backrest power recliner motor (with integral position sensor) (part of backrest frame) - LH memory power mirror - RH memory power mirror - Power adjustable memory pedals - Power adjustable steering column - Remote keyless entry transmitter Two personalized seat positions may be programmed into the memory seat system. A memory seat position may be set by first positioning the driver seat using the driver power seat switch and depressing the memory set switch. Memory seat position 1 or 2 must be selected within 5 seconds to set a personalized seat position. If position 1 or 2 is not selected within 5 seconds, the operation is aborted. This operation also aborts if any input is received from the driver power seat switch, the power mirror switch, the adjustable pedal switch, the power adjustable steering column switch or if the memory set switch is depressed again during the 5-second limit. The personalized memory seat positions are recalled using the memory switch positions 1 and 2 or with the remote keyless entry transmitter. A programmed seat position can only be recalled when the transmission selector is in PARK or NEUTRAL with the ignition switch in the RUN position. A position may be programmed at any time. For information on the DSM, refer to Body Control Systems (Multifunction Electronic Control Module). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 9914 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 9917 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9918 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9919 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9920 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 9921 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 9930 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Inoperative/DTC B117B TSB 08-14-5 07/21/08 POWER LIFT GATE INOPERATIVE - ALL FUNCTIONAL SWITCHES, REMOTE KEYLESS ENTRY, WITH POWER LIFT GATE TRUNK MODULE DTC B117B FORD: 2008 Taurus X 2007-2008 Edge, Expedition Ford: 2009 Flex LINCOLN: 2007-2008 MKX, Navigator ISSUE Some 2007-2008 Expedition, Navigator Edge, MKX, 2008 Taurus X and 2009 Flex may exhibit an inoperative power lift gate from remote keyless entry, inside switches or the outside lift gate handle with a power lift gate/trunk module (LTM) with diagnostic trouble code (DTC) B117B and PID UCH_OUT set to Active. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check power lift gate operation from all buttons. 2. If the power lift gate is inoperative, then check the LTM for DTC B117B and for PID UCH_Out set to "Active". NOTE THE PID UCH_OUT IS SET TO "INACTIVE" OR ANY OTHER DTC ARE RETRIEVED, DO NOT CONTINUE WITH THIS PROCEDURE, PERFORM NORMAL DIAGNOSTICS PER THE WORK SHOP MANUAL SECTION 501-03. 3. If both the DTC B117B and the PID UCH_Out equal "Active" are present, then clear the LTM memory and proceed to Step 4. 4. Reprogram the LTM module to the latest calibration using IDS release 55.13 Patch 28 and higher or 56.1 and higher. This new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at the website. 5. Initialize LTM per Work Shop Manual Section 501-03. 6. Check the operation of the power lift gate. Check for any DTCs. If lift gate operation passes from all switches and there are NO DTCs in the LTM, return the vehicle to the customer. 7. If any DTCs are present after retesting or lift gate is inoperative, from any switches, perform Work Shop Manual diagnosis per Section 501-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081405A 2007-2008 Expedition, 0.5 Hr. Navigator, Edge, MKX, 2008 Taurus X, 2009 Flex: Reprogram The LTM, Includes Time To Check DTCs And, Lift Gate Operation, Authorization Decal Not Required (Do Not Use With 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-14-5 > Jul > 08 > Body - Power Liftgate Inoperative/DTC B117B > Page 9936 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9937 Power Trunk / Liftgate Control Module: Locations View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9938 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9939 Power Trunk / Liftgate Control Module: Diagrams C4174A C4174B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9940 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the bolt. To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 2 bolts and the retractable running board module assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: Customer Interest A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 9952 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: All Technical Service Bulletins A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 9958 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 9959 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 9960 Seat Heater Control Module: Diagrams C3265A C3265B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 9961 C3265C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 9962 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When installing a new climate control seat module (CCSM), carry out the appropriate steps in the programmable module installation (PMI) procedure. 2. Position the front passenger seat fully upward and depower the supplemental restraint system (SRS). 3. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 4. Release the 2 tabs and slide out the CCSM. 5. Remove the CCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. If a new CCSM has been installed, carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-43 (Roof - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 9966 View 151-45 (Roof - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 9967 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9972 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Trailer Tow Relay, Left/Right Turn > Page 9973 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9976 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9977 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9978 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9979 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9980 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9981 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9982 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9983 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair ROOF OPENING PANEL MOTOR Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 9989 2. Disconnect the roof opening panel motor electrical connector and cut the tie strap. 3. Remove the roof opening panel motor. - Remove the 3 screws. Installation 1. Connect the roof opening panel motor electrical connector. Install a new tie strap and trim off excess. 2. NOTE: When installing the roof opening panel motor/module, align the 3 attach holes before engaging the drive gear into the roof opening panel drive cable. Do not rotate the motor assembly after the drive gear is engaged with the roof opening panel drive cable. Otherwise, the cable can bind. Install the roof opening panel motor. Align the attach holes, then install the 3 screws and tighten to 4 Nm (35 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 9990 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 (2007)) 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 Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Page 9994 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. 5. Slide the trough guide back to the slot (approximately 15 mm [0.6 in]) cut in track. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Page 9995 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 (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair AIR DEFLECTOR Exploded View Removal and Installation 1. Open the roof opening panel. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Page 9999 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 (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair ROOF OPENING PANEL FRAME Exploded View 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. See: Service and Repair 1. Remove the headliner. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 10003 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. Check for correct alignment of the roof opening panel. - Initialize the roof opening panel motor. Refer to Roof Opening Panel Motor Initialization. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-43 (Roof - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 10007 View 151-45 (Roof - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 10008 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel ROOF OPENING PANEL Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel > Page 10013 2. Remove the 4 roof opening panel glass screws. - 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 (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel > Page 10014 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield ROOF OPENING PANEL SHIELD Exploded View 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 glass. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel > Page 10015 2. Remove the water trough. 1 Remove the 2 screws. To install, tighten to 1 Nm (9 lb-in). 2 Remove the water trough. 3. Flex the opening shield to remove the guides from the tracks and remove the roof opening panel shield. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 10024 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 (2007)) 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 10025 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 (2007)) 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: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Sunroof / Moonroof Weatherstrip: Customer Interest Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 10030 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 10036 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 (2007)) 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 10037 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 (2007)) 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: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 10042 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10043 Sunroof / Moonroof Weatherstrip: Service and Repair ROOF OPENING PANEL WEATHERSTRIP Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10044 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10050 Memory Positioning Module: Diagrams C341A C341B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10051 C341C C341D Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10052 C341E Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 10059 C3246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation DRIVER SEAT MODULE - MEMORY SEAT The power driver seat, power outside rear view mirrors, power adjustable pedals and adjustable steering column are controlled by the driver seat module (DSM) only when the vehicle is equipped with the programmable/recall memory option. The DSM is located on the driver seat track. This system allows automatic positioning of the driver seat to 2 programmable positions. The memory seat system consists of the following components: - DSM - Driver memory seat control switch - Memory set switch - Adjustable pedal switch - Power mirror switch - Adjustable steering column switch - Memory seat track assembly (with seat position sensors integral to motors) Horizontal motor (part of seat track) - Front height motor (part of seat track) - Rear height motor (part of seat track) - Backrest power recliner motor (with integral position sensor) (part of backrest frame) - LH memory power mirror - RH memory power mirror - Power adjustable memory pedals - Power adjustable steering column - Remote keyless entry transmitter Two personalized seat positions may be programmed into the memory seat system. A memory seat position may be set by first positioning the driver seat using the driver power seat switch and depressing the memory set switch. Memory seat position 1 or 2 must be selected within 5 seconds to set a personalized seat position. If position 1 or 2 is not selected within 5 seconds, the operation is aborted. This operation also aborts if any input is received from the driver power seat switch, the power mirror switch, the adjustable pedal switch, the power adjustable steering column switch or if the memory set switch is depressed again during the 5-second limit. The personalized memory seat positions are recalled using the memory switch positions 1 and 2 or with the remote keyless entry transmitter. A programmed seat position can only be recalled when the transmission selector is in PARK or NEUTRAL with the ignition switch in the RUN position. A position may be programmed at any time. For information on the DSM, refer to Body Control Systems (Multifunction Electronic Control Module). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10067 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10068 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10069 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10070 Power Seat Motor: Locations View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10071 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10072 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10073 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10074 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10075 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10076 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10077 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10078 View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Front/Rear Height Motor > Page 10079 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10082 C3074 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10083 C3075 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10084 C3187 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10085 Power Seat Motor: Diagrams C332 C3074 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10086 C3075 C3187 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10087 C363 C382 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10088 C362 C3189 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10089 C3215 C3216 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10090 C4181 C4182 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10091 Power Seat Motor: Service and Repair POWER-FOLD SEAT MOTOR Seat Backrest - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10092 Seat Backrest - 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10093 Seat Cushion - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10094 Seat Backrest - 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10095 Seat Backrest - 60 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10096 Seat Cushion - 60 Percent Exploded View Removal and Installation NOTE: LH seat shown, RH seat similar. 1. Remove the load floor panel. 2. Remove the 2 bolts and mid-floor panel support. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10097 - Detach the 3 pin-type retainers. 3. Detach the wiring harness pin-type retainer and disconnect the affected power seat motor electrical connector. 4. NOTE: Note position of bushing shoulder for installation. Remove the bracket-to-pivot bolt and bushing from the power-fold seat motor. To install, tighten to 30 Nm (22 lb-ft). 5. Remove the bracket-to-latch bolt and power-fold seat motor. - Slide the power-fold seat motor and bracket away from the latch and torque shaft. For installation, slightly rotate the torque shaft until seated into the power-fold seat motor. - To install, tighten to 30 Nm (22 lb-ft). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10102 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10103 Power Seat Motor Position Sensor: Locations Height Sensor, Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10104 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10107 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10108 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10109 C4092 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10110 C4093 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 10115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10118 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10119 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10120 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10121 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10122 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10127 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10128 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left/Right View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10129 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10132 Power Seat Switch: Diagrams Power Seat Switch, Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10133 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10134 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10137 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10138 Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10139 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10140 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10141 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10142 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10143 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10144 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10145 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10146 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10147 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10148 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10149 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10150 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10151 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10152 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10153 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10154 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10155 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 10156 Power Seat Switch: Service and Repair MEMORY SET SWITCH Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 10157 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 10158 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 10159 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 10160 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. 1. Depower the supplemental restraint system (SRS). 2. Detach and position aside the driver seat cushion side shield cover. 3. Release the clips and remove the memory set switch. - Disconnect the seat control switch. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement Seat Backrest - Front, 40 Percent SEAT BACKREST - FRONT, 40 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10165 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10166 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10167 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10168 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger seat similar. All seats 1. Remove the affected seat and depower the supplemental restraint system (SRS). 2. If equipped, release the tab and remove the manual recliner lever handle. 3. If equipped, remove the manual lumbar control knob. - Adjust the manual lumbar to the fully relaxed position. - Pull outward and remove the manual lumbar knob. 4. Detach and remove the cushion side shield cover. - If equipped, disconnect the seat control switch. - If equipped, disconnect the memory set switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10169 Power seat with manual recliner 5. Remove the seat control switch knob. 6. Remove the cushion side shield cover forward screw. 7. CAUTION: Do not damage the manual recliner lever when removing the cushion side shield cover. Remove the cushion side shield cover. Partially remove the cover to gain access to the seat control switch. - Release the retainers and detach the seat control switch from the side shield cover. - Remove the cushion side shield cover. All seats 8. NOTE: For power seats, note the wiring harness routing for installation. Remove the 5 screws and cushion side shield. Detach the pin-type retainer. - If equipped, route out the wiring harness. 9. Release the backrest lower J-strip and unzip the 2 side zippers. Seats with manual lumbar 10. NOTE: The lumbar support assembly must be fully relaxed. Remove the manual lumbar actuator. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10170 - Remove the 2 screws. - Remove the manual lumbar actuator. - Detach the lumbar cable. 11. NOTE: Note manual lumbar cable routing for installation. Route the manual lumbar cable from the backrest. 12. NOTE: Note the position of the side air bag module locator pin to the seat backrest frame for installation. Remove the 2 side air bag module nuts. To install, tighten to 10 Nm (89 lb-in). 13. NOTE: Note the position of the side air bag module locator pin and mounting studs in the seat backrest trim cover deployment chute for installation. Position the seat backrest foam aside and remove the side air bag module from the backrest frame. Then slide the side air bag module out of the seat backrest trim cover deployment chute. 14. Disconnect the electrical connector and remove the side air bag module. 15. NOTE: Note wiring harness routing for installation. Detach the 3 pin-type retainers and route out the side air bag wiring harness. Power and climate controlled seats Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10171 16. Disconnect the backrest wiring harness electrical connector. 17. NOTE: Note wiring harness routing for installation. Route the backrest wiring harness from the cushion. All seats 18. Release the cushion trim cover rear hook and loop strip from the inboard side. 19. Remove the 4 backrest frame-to-seat track bolts and backrest. - To install, tighten to 45 Nm (33 lb-ft). 20. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To install, reverse the removal procedure. 21. Install the seat and repower the SRS. Seat Backrest - Front, 60 Percent SEAT BACKREST - FRONT, 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10172 Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10173 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10174 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10175 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10176 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the front 60 percent seat and depower the supplemental restraint system (SRS). 2. Release tab and remove the manual recliner lever handle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10177 3. Remove the cushion side shield cover. - Remove the forward screw. - Detach the retainer clips and remove the cover. 4. Remove the 5 screws and cushion side shield. 5. Release the backrest lower J-strip and unzip the 2 side zippers. 6. NOTE: Note the position of the side air bag module locator pin to the seat backrest frame for installation. Remove the 2 side air bag module nuts. To install, tighten to 10 Nm (89 lb-in). 7. NOTE: Note the position of the side air bag module locator pin and mounting studs in the seat backrest trim cover deployment chute for installation. Position the seat backrest foam aside and remove the side air bag module from the backrest frame. Then slide the side air bag module out of the seat backrest trim cover deployment chute. 8. Disconnect the electrical connector and remove the side air bag module. 9. NOTE: Note wiring harness routing for installation. Route the backrest wiring harness from the cushion. Detach the clip and 3 pin-type retainers. 10. Remove the 4 backrest frame-to-seat track bolts and backrest. - To install, tighten to 45 Nm (33 lb-ft). 11. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 12. Install the 60 percent seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10178 Seat Backrest - Second Row, 20 Percent SEAT BACKREST - SECOND ROW, 20 PERCENT Seat Backrest - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10179 Seat Backrest - 20 Percent (Part 2) Seat Cushion - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10180 Seat Cushion - 20 Percent (Part 2) Seat Backrest - 40 Percent Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10181 Seat Cushion - 40 Percent Seat (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10182 Seat Cushion - 40 Percent Seat (Part 2) Exploded View Removal and Installation 1. Remove the 20 percent seat from the vehicle. 2. Remove the screw and pivot bolt cover. - Route the attaching strap through the pivot bolt cover. 3. Release the 2 lower backrest trim cover J-clips. 4. Remove the pin-type retainer and detach the LH side attaching strap. 5. Remove the 2 screws and RH side shield. - Raise the backrest upright to access and remove the center screw. - Release the 2 pin-type retainers. 6. NOTE: Note attaching strap routing for installation. Remove the pin-type retainer and detach the RH attaching strap. 7. Remove the bolt and detach the safety belt retractor anchor. - To install, tighten to 55 Nm (41 lb-ft). 8. Remove the 2 pin-type retainers and lower panel. 9. Release the 3 lower backrest J-clips and route the RH trim cover flap through the child safety seat lower anchor and tether for children (LATCH) anchor. 10. Detach the 2 J-clips and remove the attaching straps. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10183 11. Detach the cable end and latch release cable from the seat base. 12. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-an-loop strip can be torn from the cushion foam pad. Partially invert the backrest trim cover to access the backrest fasteners. 13. Position aside the foam pad and remove the 2 swivel bolts. - To install, tighten to 30 Nm (22 lb-ft). 14. Remove the pivot bolt. - To install, tighten to 55 Nm (41 lb-ft). 15. Remove the 2 backrest-to-cushion bolts. - To install, tighten to 40 Nm (30 lb-ft). 16. NOTE: Note cable routing for installation. Remove the seat backrest. Route out the latch release cable. 17. To install, reverse the removal procedure. Seat Backrest - Third Row, 40 Percent SEAT BACKREST - THIRD ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10184 Seat Backrest - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10185 Seat Backrest - 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10186 Seat Cushion - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10187 Seat Backrest - 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10188 Seat Backrest - 60 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10189 Seat Cushion - 60 Percent Exploded View Removal and Installation All seats 1. Remove the third row 40 percent seat. 2. Remove the 2 screws and the inboard and outboard slide bracket covers. 3. Release the backrest trim cover lower and inboard J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10190 Manual fold seat 4. Remove the manual seat cable. 1 Pinch the cable end and remove the cable from the retainer. 2 Release the cable end hook from the retaining hole. All seats 5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch nuts. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the inboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts. - To install, tighten to 15 Nm (11 lb-ft). 7. Remove the backrest from the cushion. 8. To install, reverse the removal procedure. Seat Backrest - Third Row, 60 Percent SEAT BACKREST - THIRD ROW, 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10191 Seat Backrest - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10192 Seat Backrest - 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10193 Seat Cushion - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10194 Seat Backrest - 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10195 Seat Backrest - 60 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10196 Seat Cushion - 60 Percent Exploded View Removal and Installation All seats 1. Remove the third row 60 percent seat. 2. Remove the 2 screws and the inboard and outboard slide bracket covers. 3. Release the backrest trim cover lower and inboard J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10197 Manual fold seats 4. Remove the manual seat cable. 1 Pinch the cable end and remove the cable from retainer. 2 Release the cable end hook from the retaining hole. All seats 5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch nuts. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the inboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts. - To install, tighten to 15 Nm (11 lb-ft). 7. Remove the backrest from the cushion. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10198 Seat Back: Overhaul Seat Backrest - Front SEAT BACKREST - FRONT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10199 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Remove the backrest assembly. 3. Remove the head restraint. - Push in the RH guide button to release and remove the head restraint. 4. Raise the rear trim cover flap and release the inner J-clip. 5. NOTE: The head restraint guides are not interchangeable. Note location for installation. Remove the headrest guides. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10200 - Reach into the backrest and pinch the headrest guide ends together to release from the backrest frame. - Pull the backrest trim cover away from the spring clips while pulling out the headrest guides. 6. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Partially invert the backrest trim cover and remove the lower hog rings from the support wires. 7. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. NOTE: Note the side air bag module deployment chute routing for installation. Continue to invert the trim cover and remove the upper hog rings. Route the side air bag module deployment chute through the slot in the foam pad. 8. Remove the backrest trim cover. 9. Release the lower flap from the backrest frame hooks and remove the backrest foam pad. 10. Remove the 4 bolts and lumbar assembly. - To install, tighten to 7 Nm (62 lb-in). - If equipped, disconnect the electrical connector from the lumbar assembly. - If equipped, route out the manual lumbar cable. Climate controlled seats 11. Remove the climate controlled seat thermo-electric device (TED). - Disconnect the TED electrical connector. - Remove the scrivet. - Detach the 2 retainer clips from the backrest frame support wires. Seats with power recliner 12. Disconnect the recliner motor electrical connector. Power and climate controlled seats 13. NOTE: Note the wiring harness routing for installation. Detach the clip and pin-type retainer and remove the backrest wiring harness. All seats Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10201 14. WARNING: - Check the air bag deployment chute for damage. The air bag deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the air bag cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 15. Install the backrest assembly. 16. Install the seat and repower the SRS. Seat Backrest - Second Row, 20 Percent SEAT BACKREST - SECOND ROW, 20 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10202 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10203 Part 2 Disassembly and Assembly 1. Remove the 20 percent seat. 2. Remove the 20 percent seat backrest. 3. Remove the safety belt guide cover. - Insert an appropriate tool into the holes and release the 3 locking tabs. - Detach the safety belt guide cover. - Route the safety belt webbing through the slot. 4. Remove the latch release handle bezel. - Release the upper tab and separate the bezel from the latch release handle. 5. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. 6. Remove the row of hog rings. 7. Continue inverting and remove the backrest trim cover. - Route the safety belt webbing through the trim cover opening. 8. Remove the 2 pin-type retainers and foam pad. 9. Remove the safety belt retractor foam cover. 10. Remove the 2 screws and safety belt retractor cover. 11. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 12. Release the 2 tabs and detach the safety belt retractor guide. 13. NOTE: - Note safety belt routing for installation. - Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10204 Remove the safety belt retractor. Route out the safety belt webbing, guide, tongue and anchor through the backrest frame. 14. Release the pin-type retainer and detach the release cable from the backrest frame. 15. NOTE: Note cable routing for installation. Remove the 2 screws and latch release handle. Route out the release cable. 16. Remove the 2 pin-type retainers and 2 attaching straps. 17. Remove the 8 backrest support panel screws. 18. To assemble, reverse the disassembly procedure. - Verify the safety belt retractor operates without excessive effort or binding. Seat Backrest - Third Row, 40 Percent SEAT BACKREST - THIRD ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10205 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10206 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10207 Part 3 Disassembly and Assembly All seats 1. Remove the third row 40 percent seat. 2. Remove the third row 40 percent seat backrest. 3. Remove the bolt and the safety belt buckle. - During assembly make sure anti-rotation tab is engaged into seat locator. - To install, tighten to 40 Nm (30 lb-ft). 4. Release the backrest trim cover outboard J-clip. 5. Remove all the staples. 6. NOTE: - Note the spring clip position for installation. - Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. Pull the trim cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. - Raise and remove the head restraint. Manual seat 7. NOTE: Note cable routing for installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10208 Remove the 2 screws and the manual latch handle and cable assembly. Route out the cable. All seats 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 backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. 10. Remove the row of hog rings and backrest trim cover. 11. Remove the nut, screw and support bracket. 12. Remove the 2 inboard latch-to-backrest frame bolts and the inboard latch. - To install, tighten to 40 Nm (30 lb-ft). 13. Remove the outboard latch-to-cushion frame bolt and the outboard latch. - To install, tighten to 30 Nm (22 lb-ft). 14. Remove the 6 screws and the backrest support panel. 15. To assemble, reverse the disassembly procedure. Seat Backrest - Third Row, 60 Percent SEAT BACKREST - THIRD ROW, 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10209 60 Percent Backrest (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10210 60 Percent Backrest (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10211 60 Percent Backrest (Part 3) Disassembly and Assembly All seats 1. Remove the third row 60 percent seat. 2. Remove the third row 60 percent seat backrest. 3. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: - Note the spring clip position for installation. - Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. Pull the trim cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. - Raise and remove the head restraint. 5. Release all the backrest trim cover J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10212 6. Remove all the staples. 7. Release the hook-and-loop strip. Manual seat 8. NOTE: Note cable routing for installation. Remove the 2 screws and the manual latch handle and cable assembly. Route out the cable. All seats 9. Remove the safety belt guide cover. 10. NOTE: The head restraint sleeve pins are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release and pull the 2 head restraint guides out. 11. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. 12. Remove the row of hog rings. 13. Remove the trim cover. - Route the safety belt webbing through the trim cover. 14. Remove the backrest foam pad. 15. Remove the nut, screw and support bracket. 16. Remove the outboard latch-to-cushion frame bolt and outboard latch. - To install, tighten to 35 Nm (26 lb-ft). 17. Remove the 2 inboard latch-to-backrest frame bolts and the inboard latch. - To install, tighten to 55 Nm (41 lb-ft). 18. Remove the 4 screws and the safety belt retractor cover. 19. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 20. Pinch to release the safety belt guide and remove the safety belt retractor. - Route through the backrest frame. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 10213 21. Remove the 15 screws and the backrest support panel. 22. Remove the bolt and child safety seat tether anchor. - To install, tighten to 15 Nm (11 lb-ft). 23. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent Seat Cover: Service and Repair Seat Backrest Cover - Front, 40 Percent SEAT BACKREST COVER - FRONT, 40 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10218 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10219 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10220 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10221 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat and depower the SRS. 2. Remove the backrest assembly. 3. Remove the head restraint. - Push in the RH guide button to release and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10222 4. Raise the rear trim cover flap and release the inner J-clip. 5. NOTE: The head restraint guides are not interchangeable. Note location for installation. Remove the headrest guides. Reach into the backrest and pinch the headrest guide ends together to release from the backrest frame. - Pull the backrest trim cover away from the spring clips while pulling out the headrest guides. 6. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Partially invert the backrest trim cover and remove the lower hog rings from the support wires. 7. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. NOTE: Note the side air bag module deployment chute routing for installation. Continue to invert the trim cover and remove the upper hog rings. - Route the side air bag module deployment chute through the slot in the foam pad. 8. Remove the backrest trim cover. 9. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10223 - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 10. Install the backrest assembly. 11. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10224 Seat Cover: Service and Repair Seat Backrest Cover - Front, 60 Percent SEAT BACKREST COVER - FRONT, 60 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10225 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10226 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10227 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10228 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat and depower the SRS. 2. Remove the backrest assembly. 3. Remove the head restraint - Push in the RH guide button to release and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10229 4. Raise the rear trim cover flap and release the inner J-clip. 5. NOTE: The head restraint guides are not interchangeable. Note location for installation. Remove the headrest guides. Reach a hand into the backrest and pinch the headrest guide ends together to release from the backrest frame. - Pull the backrest trim cover away from the spring clips while pulling out the headrest guides. 6. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Partially invert the backrest trim cover and remove the lower hog rings from the support wires. 7. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. NOTE: Note the side air bag module deployment chute routing for installation. Continue to invert the trim cover and remove the upper hog rings. Route the side air bag module deployment chute through the slot in the foam pad. 8. Remove the trim cover. 9. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10230 foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 10. Install the backrest assembly. 11. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10231 Seat Cover: Service and Repair Seat Cushion Cover - Front, 40 Percent SEAT CUSHION COVER - FRONT, 40 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10232 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10233 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10234 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10235 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Release the cushion trim cover front and rear J-clips and hook-and-loop strip. 3. NOTE: - Note wiring harness routing for installation. - Use care when removing the thermo-electric device (TED). The U-nuts can slip into the cushion frame. If equipped, remove the climate controlled seat thermo-electric device (TED). Disconnect the electrical connector. - Detach the pin-type retainer and wiring harness. - Remove the 2 screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10236 - Route the wiring harness and remove the TED. 4. Remove the cushion frame from the seat track. - Remove the 4 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion frame. 5. Release the 2 cushion trim cover retainer clips and remove the trim cover and 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. Partially invert the cushion trim cover to the row of hog rings and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. 7. To install, reverse the removal procedure. 8. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10237 Seat Cover: Service and Repair Seat Cushion Cover - Front, 60 Percent SEAT CUSHION COVER - FRONT, 60 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10238 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10239 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10240 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10241 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the 60 percent seat and depower the supplemental restraint system (SRS). 2. Release the cushion trim cover front and rear J-clips and hook-and-loop strips. 3. Remove the 2 cushion frames from the seat track. - Remove the 8 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 4 cushion frame rear clips and straps from the seat track and remove both cushion frames. 4. Release the 4 cushion trim cover retainer clips and remove the trim cover and foam pad from the cushion frames. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10242 5. 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. Partially invert the cushion trim cover and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. 6. To install, reverse the removal procedure. 7. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10243 Seat Cover: Service and Repair Seat Backrest Cover - Front, 40 Percent SEAT BACKREST COVER - FRONT, 40 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10244 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10245 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10246 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10247 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat and depower the SRS. 2. Remove the backrest assembly. 3. Remove the head restraint. - Push in the RH guide button to release and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10248 4. Raise the rear trim cover flap and release the inner J-clip. 5. NOTE: The head restraint guides are not interchangeable. Note location for installation. Remove the headrest guides. Reach into the backrest and pinch the headrest guide ends together to release from the backrest frame. - Pull the backrest trim cover away from the spring clips while pulling out the headrest guides. 6. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Partially invert the backrest trim cover and remove the lower hog rings from the support wires. 7. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. NOTE: Note the side air bag module deployment chute routing for installation. Continue to invert the trim cover and remove the upper hog rings. - Route the side air bag module deployment chute through the slot in the foam pad. 8. Remove the backrest trim cover. 9. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10249 - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 10. Install the backrest assembly. 11. Install the seat and repower the SRS. Seat Backrest Cover - Front, 60 Percent SEAT BACKREST COVER - FRONT, 60 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10250 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10251 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10252 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10253 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be replaced if necessary. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat and depower the SRS. 2. Remove the backrest assembly. 3. Remove the head restraint - Push in the RH guide button to release and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10254 4. Raise the rear trim cover flap and release the inner J-clip. 5. NOTE: The head restraint guides are not interchangeable. Note location for installation. Remove the headrest guides. Reach a hand into the backrest and pinch the headrest guide ends together to release from the backrest frame. - Pull the backrest trim cover away from the spring clips while pulling out the headrest guides. 6. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Partially invert the backrest trim cover and remove the lower hog rings from the support wires. 7. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. NOTE: Note the side air bag module deployment chute routing for installation. Continue to invert the trim cover and remove the upper hog rings. Route the side air bag module deployment chute through the slot in the foam pad. 8. Remove the trim cover. 9. WARNING: - Check the side air bag module deployment chute for damage. The side air bag module deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10255 foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - If the side air bag module cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury, in the event of an air bag deployment. To assemble, reverse the disassembly procedure. 10. Install the backrest assembly. 11. Install the seat and repower the SRS. Seat Cushion Cover - Front, 40 Percent SEAT CUSHION COVER - FRONT, 40 PERCENT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10256 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10257 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10258 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10259 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Release the cushion trim cover front and rear J-clips and hook-and-loop strip. 3. NOTE: - Note wiring harness routing for installation. - Use care when removing the thermo-electric device (TED). The U-nuts can slip into the cushion frame. If equipped, remove the climate controlled seat thermo-electric device (TED). Disconnect the electrical connector. - Detach the pin-type retainer and wiring harness. - Remove the 2 screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10260 - Route the wiring harness and remove the TED. 4. Remove the cushion frame from the seat track. - Remove the 4 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion frame. 5. Release the 2 cushion trim cover retainer clips and remove the trim cover and 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. Partially invert the cushion trim cover to the row of hog rings and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. 7. To install, reverse the removal procedure. 8. Install the seat and repower the SRS. Seat Cushion Cover - Front, 60 Percent SEAT CUSHION COVER - FRONT, 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10261 Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10262 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10263 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10264 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10265 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the 60 percent seat and depower the supplemental restraint system (SRS). 2. Release the cushion trim cover front and rear J-clips and hook-and-loop strips. 3. Remove the 2 cushion frames from the seat track. - Remove the 8 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 4 cushion frame rear clips and straps from the seat track and remove both cushion frames. 4. Release the 4 cushion trim cover retainer clips and remove the trim cover and foam pad from the cushion frames. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10266 5. 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. Partially invert the cushion trim cover and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. 6. To install, reverse the removal procedure. 7. Install the seat and repower the SRS. Seat Backrest Cover - Second Row, 20 Percent SEAT BACKREST COVER - SECOND ROW, 20 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10267 Seat Backrest - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10268 Seat Backrest - 20 Percent (Part 2) Seat Cushion - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10269 Seat Cushion - 20 Percent (Part 2) Seat Backrest - 40 Percent Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10270 Seat Cushion - 40 Percent Seat (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10271 Seat Cushion - 40 Percent Seat (Part 2) Exploded View Removal and Installation 1. Remove the 20 percent seat from the vehicle. 2. Remove the screw and pivot bolt cover. - Route the attaching strap through the pivot bolt cover. 3. Release the 2 lower backrest trim cover J-clips. 4. Remove the pin-type retainer and detach the LH side attaching strap. 5. Remove the 2 screws and RH side shield. - Raise the backrest upright to access and remove the center screw. - Release the 2 pin-type retainers. 6. NOTE: Note attaching strap routing for installation. Remove the pin-type retainer and detach the RH attaching strap. 7. Remove the bolt and detach the safety belt retractor anchor. - To install, tighten to 55 Nm (41 lb-ft). 8. Remove the 2 pin-type retainers and lower panel. 9. Release the 3 lower backrest J-clips and route the RH trim cover flap through the child safety seat lower anchor and tether for children (LATCH) anchor. 10. Detach the 2 J-clips and remove the attaching straps. 11. Remove the safety belt guide cover. - Insert an appropriate tool into the holes and release the 3 locking tabs. - Detach the safety belt guide cover. - Route the safety belt webbing through the slot. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10272 12. Remove the latch release handle bezel. - Release the upper tab and separate the bezel from the latch release handle. 13. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-an-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. 14. Remove the row of hog rings. 15. Continue inverting and remove the backrest trim cover. - Route the safety belt webbing through the trim cover opening. 16. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, 40 Percent SEAT BACKREST COVER - SECOND ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10273 Seat Backrest - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10274 Seat Backrest - 20 Percent (Part 2) Seat Cushion - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10275 Seat Cushion - 20 Percent (Part 2) Seat Backrest - 40 Percent Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10276 Seat Cushion - 40 Percent Seat (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10277 Seat Cushion - 40 Percent Seat (Part 2) Exploded View Removal and Installation 1. NOTE: - Note the spring clip position for installation. - Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. Pull the trim cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. - Raise and remove the head restraint. 2. Position the backrest downward. 3. Remove the kneeling release (cargo mode) handle. - Raise the handle to access the cable. - Detach the cable jacket from the kneeling release handle. - Release the retainers and position aside the kneeling release handle. 4. Release the lower backrest trim cover J-clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10278 5. Position aside the backrest trim cover rear flap and remove the 4 pin-type retainers. 6. Raise the backrest upright and route the backrest trim cover from between the cushion and backrest. 7. 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 pad. Invert the backrest trim cover to the row of hog rings. Separate the hook-and-loop strips. 8. Remove the row of hog rings. 9. Continue inverting the backrest trim cover to the head restraint guides. 10. CAUTION: Be careful not to tear the material when separating the head restraints and spring clips from the backrest trim cover. Pinch the head restraint guide ends to release and remove the 2 head restraint guides. Separate the head restraint guides from the backrest trim cover. 11. Remove the backrest trim cover. 12. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 20 Percent SEAT CUSHION COVER - SECOND ROW, 20 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10279 Seat Backrest - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10280 Seat Backrest - 20 Percent (Part 2) Seat Cushion - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10281 Seat Cushion - 20 Percent (Part 2) Seat Backrest - 40 Percent Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10282 Seat Cushion - 40 Percent Seat (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10283 Seat Cushion - 40 Percent Seat (Part 2) Exploded View Removal and Installation 1. Remove the 20 percent seat. 2. Release the 2 backrest trim cover lower J-clips. 3. Remove the screw and pivot bolt cover. - Route out the attaching strap. 4. Remove the 2 pin-type retainers and lower panel. 5. Release the cushion trim cover rear J-clip. - Position the backrest downward to aid in trim cover removal. - Route the cushion trim cover rear flap and J-clip from between the cushion and backrest. 6. Release the hook-and-loop strip and remaining cushion J-clips. 7. Remove the cushion foam pad and trim cover. 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 foam. Release the hook-and-loop strips and invert the cushion trim cover to the row of hog rings. 9. Remove the hog rings and cushion trim cover. 10. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 40 Percent SEAT CUSHION COVER - SECOND ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10284 Seat Backrest - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10285 Seat Backrest - 20 Percent (Part 2) Seat Cushion - 20 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10286 Seat Cushion - 20 Percent (Part 2) Seat Backrest - 40 Percent Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10287 Seat Cushion - 40 Percent Seat (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10288 Seat Cushion - 40 Percent Seat (Part 2) Exploded View Removal and Installation 1. Place the seat in the E-Z entry position. 2. Release the trim cover J-clips from both sides of the cushion. 3. Release the outer and inner rear J-clips from the cushion. 4. Latch the seat to the floor and raise the backrest. 5. Release the front J-clip from the cushion. 6. Release the 2 cushion trim cover retainers from the 2 child safety seat LATCH anchors. - Pull the cushion trim cover rearward and release the 2 clips. 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. Separate the hook-and-loop strips and invert the cushion trim cover to the row of hog rings. 8. Remove the row of hog rings. 9. Remove the cushion trim cover. - Route the trim cover from between the cushion and backrest. 10. To install, reverse the removal procedure. Seat Backrest Cover - Third Row SEAT BACKREST COVER - THIRD ROW Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10289 Seat Backrest - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10290 Seat Backrest - 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10291 Seat Cushion - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10292 Seat Backrest - 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10293 Seat Backrest - 60 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10294 Seat Cushion - 60 Percent Exploded View Removal and Installation NOTE: LH seat shown, RH seat similar. All seats 1. Remove the affected seat. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10295 2. Remove the seat backrest. 3. NOTE: - Note the spring clip position for installation. - Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. Pull the trim cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. - Raise and remove the head restraint. 4. Release all the backrest trim cover J-clips. 5. Remove all the staples. LH seat 6. Release the hook-and-loop strip. 7. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 8. Remove the safety belt guide cover. Manual fold seat 9. NOTE: Note cable routing for installation. Remove the 2 screws and the manual latch handle and cable assembly. - Route out the cable. All seats 10. NOTE: The head restraint sleeve pins 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. 11. CAUTION: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. 12. Remove the row of hog rings. 13. Remove the trim cover. - For LH seat backrest, route the safety belt webbing through the trim cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10296 14. To install, reverse the removal procedure. Seat Cushion Cover - Third Row SEAT CUSHION COVER - THIRD ROW Seat Backrest - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10297 Seat Backrest - 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10298 Seat Cushion - 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10299 Seat Backrest - 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10300 Seat Backrest - 60 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10301 Seat Cushion - 60 Percent Exploded View Removal and Installation NOTE: LH seat shown, RH seat similar. 1. Remove the affected seat. 2. Raise the cushion and release the trim cover hook-and-loop strips and J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front, 40 Percent > Page 10302 3. Remove the cushion trim cover and foam pad from the cushion frame. 4. 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. Separate the hook-and-loop strips and invert the trim cover to the row of hog rings. 5. Remove the row of hog rings and remove the trim cover. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent Seat Cushion: Service and Repair Seat Cushion - Front, 40 Percent SEAT CUSHION - FRONT, 40 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10307 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Remove the seat backrest. 3. Release the cushion trim cover front and rear J-clips and rear hook-and-loop strip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10308 4. Remove the safety belt buckle pretensioner. - Remove the tie strap. - Disconnect the 2 safety belt buckle pretensioner electrical connectors. - Remove the nut and safety belt buckle pretensioner. To install, tighten to 55 Nm (41 lb-ft). Climate controlled seats 5. NOTE: - Use care when removing the thermo-electric device (TED). The U-nuts can slip into the cushion frame. - Note wiring harness routing for installation. Remove the climate controlled seat thermo-electric device (TED). Disconnect the electrical connector. - Detach the pin-type retainer and wiring harness. - Remove the 2 screws. - Route the wiring harness and remove the TED. 6. Release the 2 tabs and slide out the climate control seat module (CCSM). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10309 7. NOTE: When installing a new climate control seat module (CCSM), it is necessary to carry out programmable module installation (PMI). If passenger seat, remove the CCSM. Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. Driver memory seat 8. Remove the driver seat module (DSM). - Disconnect the 5 electrical connectors. - Release the 2 tabs and slide out the DSM. All seats 9. Remove the cushion frame from the seat track. - Remove the 4 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion frame. 10. Release the 2 cushion trim cover retainer clips and remove the trim cover and foam pad from the cushion frame. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10310 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. Remove the cushion trim cover. Partially invert the cushion trim cover and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. Driver seat 12. Disconnect the SRS seat position sensor electrical connector and detach the wiring harness pin-type retainer. Power seat 13. Disconnect the seat track motor electrical connectors. - For power seat track, disconnect the 3 motor electrical connectors. - For memory seat track, disconnect the 6 motor electrical connectors. 14. NOTE: Note wiring harness routing for installation. Remove the wiring harness. Remove the 3 wiring harness bracket screws. - Remove the tie strap and release the rear wiring harness bracket clip from the seat track. - Separate the electrical connectors and wiring harness from the seat track. - Route and remove the wiring harness and bracket. Manual seat 15. Remove the inboard and outboard seat track rails. - Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails. To install, tighten to 30 Nm (22 lb-ft). - Remove the inboard and outboard seat track rails. - Release and separate the seat track adjust handle from the seat track rails. - NOTE: Note the spring position for installation. Disconnect the spring. - Slightly bend the tab and detach the seat adjust handle from the inboard seat track rail. All seats 16. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10311 17. Install the seat backrest. 18. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10312 Seat Cushion: Service and Repair Seat Cushion - Front, 60 Percent SEAT CUSHION - FRONT, 60 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10313 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. Depower the supplemental restraint system (SRS). 2. Remove the 60 percent seat. 3. Remove the 60 percent seat backrest. 4. Separate and remove the armrest bracket inner and outer covers. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10314 5. Open the armrest latch lower cover. 6. Remove the armrest and brackets from the seat track. - Remove the 2 armrest latch-to-seat track bolts. To install, tighten to 45 Nm (33 lb-ft). - Remove the 2 armrest bracket-to-seat track bolts. To install, tighten to 45 Nm (33 lb-ft). Armrest disassembly 7. Remove the screw, release the clips and remove the armrest latch upper cover. 8. Detach the 2 pin-type retainers and remove the armrest latch lower cover. 9. Remove the armrest pivot bolt and armrest bracket. - To install, tighten to 35 Nm (26 lb-ft). 10. Remove the 2 armrest latch bolts and armrest latch. - To install, tighten to 45 Nm (33 lb-ft). All seats 11. Release the cushion trim cover front and rear J-clips. 12. Remove the center seat safety belt bolt and center seat safety belt. - To install, tighten to 55 Nm (41 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10315 13. Remove the safety belt buckle pretensioner. - Remove the tie strap. - Disconnect the 2 safety belt buckle pretensioner electrical connectors. - Remove the nut and safety belt buckle pretensioner. To install, tighten to 55 Nm (41 lb-ft). 14. Remove the 2 cushion frames from the seat track. - Remove the 8 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 4 cushion frame rear clips and straps from the seat track and remove both cushion frames. 15. Release the 4 cushion trim cover retainer clips and remove the trim cover and foam pad from the cushion frames. 16. 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. Partially invert the cushion trim cover and separate the hook-and-loop strips. - Remove the hog rings and separate the trim cover and foam pad. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10316 17. Remove the inboard and outboard seat track rails. - Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails. To install, tighten to 30 Nm (22 lb-ft). - Remove the inboard and outboard seat track rails. - Release and separate the seat track adjust handle from the seat track rails. - NOTE: Note the spring position for installation. Disconnect the spring. - Slightly bend the tab and detach the seat adjust handle from the inboard seat track rail. 18. NOTE: Note wiring harness routing for installation. Remove the wiring harness. Remove the 3 wiring harness bracket screws. - Remove the tie strap and release the rear wiring harness bracket clip from the seat track. - Separate the electrical connectors and wiring harness from the seat track. - Route and remove the wiring harness and bracket. 19. To assemble, reverse the disassembly procedure. 20. Install the 60 percent seat backrest. 21. Install the 60 percent seat. 22. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10317 Seat Cushion: Service and Repair Seat Cushion - Second Row, 20 Percent SEAT CUSHION - SECOND ROW, 20 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10318 Part 2 Disassembly and Assembly 1. Remove the 20 percent seat. 2. Remove the 20 percent seat backrest. 3. Remove the 2 screws and LH side shield. 4. Remove the nut and safety belt buckle. - To install, align the anti-rotation tab. To install, tighten to 55 Nm (41 lb-ft). 5. Release the cushion trim cover front J-clip. 6. Remove the 2 riser-to-cushion frame bolts and cushion frame. - To install, tighten to 30 Nm (22 lb-ft). 7. Release the hook-and-loop strip and remaining cushion J-clips. 8. Remove the cushion frame from the foam pad and trim cover. 9. 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. Release the hook-and-loop strips and invert the cushion trim cover to the row of hog rings. 10. Remove the hog rings and cushion trim cover. 11. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10319 Seat Cushion: Service and Repair Seat Cushion - Third Row, 40 Percent SEAT CUSHION - THIRD ROW, 40 PERCENT 40 Percent Cushion (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10320 40 Percent Cushion (Part 2) 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 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. Separate the hook-and-loop strips and invert the trim cover to the row of hog rings. 7. Remove the row of hog rings and remove the trim cover. 8. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10321 Seat Cushion: Service and Repair Seat Cushion - Third Row, 60 Percent SEAT CUSHION - THIRD ROW, 60 PERCENT 60 Percent Cushion (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front, 40 Percent > Page 10322 60 Percent Cushion (Part 2) 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. - 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. Separate the hook-and-loop strips and invert the trim cover to the row of hog rings. 7. Remove the row of hog rings and remove the trim cover. 8. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 07-22-4 > Nov > 07 > A/C - Poor Seat Cooling Performance Seat Fan: Customer Interest A/C - Poor Seat Cooling Performance TSB 07-22-4 11/12/07 POOR SEAT COOLING PERFORMANCE - BUILT BEFORE 7/16/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-15-5 to update the Service Procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/16/2007 and equipped with climate control seats, may exhibit poor cooling performance in the seat. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Verify there are no diagnostic trouble codes (DTCs) and that the thermal emitting device and fan assemblies are working properly. Then use IDS to select the Maximum Output Mode. This will increase fan speed to provide quicker cooling. 1. Using IDS (equipped with release B51.5 or higher) normally ID the vehicle. 2. Select "Toolbox" at the top of the screen. 3. Select "Module Programming" from the menu. 4. Select "Programmable Parameters". 5. Select "Climate Control Seats". 6. Select "High Cool Blower Voltage" to change setting. 7. Select "Maximum Output Mode". 8. After the preference has been successfully changed, verify that the seat fan assemblies are operating according to the new setting. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072204A 2007-2008 0.3 Hr. Expedition/Navigator Vehicles Built Before 7/16/2007: Check For DTCs, Then Change The High Cool Blower Voltage to Maximum Output (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 07-22-4 > Nov > 07 > A/C - Poor Seat Cooling Performance > Page 10331 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Fan: Customer Interest A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 10336 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 07-22-4 > Nov > 07 > A/C - Poor Seat Cooling Performance Seat Fan: All Technical Service Bulletins A/C - Poor Seat Cooling Performance TSB 07-22-4 11/12/07 POOR SEAT COOLING PERFORMANCE - BUILT BEFORE 7/16/2007 FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator This article supersedes TSB 07-15-5 to update the Service Procedure. ISSUE Some 2007-2008 Expedition and Navigator vehicles built before 7/16/2007 and equipped with climate control seats, may exhibit poor cooling performance in the seat. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Verify there are no diagnostic trouble codes (DTCs) and that the thermal emitting device and fan assemblies are working properly. Then use IDS to select the Maximum Output Mode. This will increase fan speed to provide quicker cooling. 1. Using IDS (equipped with release B51.5 or higher) normally ID the vehicle. 2. Select "Toolbox" at the top of the screen. 3. Select "Module Programming" from the menu. 4. Select "Programmable Parameters". 5. Select "Climate Control Seats". 6. Select "High Cool Blower Voltage" to change setting. 7. Select "Maximum Output Mode". 8. After the preference has been successfully changed, verify that the seat fan assemblies are operating according to the new setting. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072204A 2007-2008 0.3 Hr. Expedition/Navigator Vehicles Built Before 7/16/2007: Check For DTCs, Then Change The High Cool Blower Voltage to Maximum Output (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 07-22-4 > Nov > 07 > A/C - Poor Seat Cooling Performance > Page 10342 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Fan: All Technical Service Bulletins A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 10347 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative Seat Heater: Customer Interest A/C - Climate Seat Function Inoperative TSB 08-23-11 11/24/08 INOPERATIVE OR NO COMMUNICATION WITH DUAL CLIMATE CONTROL SEAT MODULE (DCSM) FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 MKZ, MKX, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles may exhibit inoperative climate seat function with no communication to the DCSM due to a ground concern. ACTION Follow service procedure to correct concern. SERVICE PROCEDURE NOTE THIS PROCEDURE ONLY APPLIES IF DAMAGE HAS BEEN IDENTIFIED AT THE SPECIFIC CONNECTOR AND PIN. IF DAMAGE IS NOT VISIBLE AT THE SPECIFIC CONNECTOR AND PIN, THIS PROCEDURE DOES NOT APPLY AND CONTINUE WITH NORMAL DIAGNOSTICS IN THE APPROPRIATE WORKSHOP MANUAL. Refer to Workshop Manual (WSM), Section 501-10 to gain access to the DCSM connector. Seat removal may be required. Zephyr-MKZ: If Connector C3305A is damaged at Pin M GD139 (BK-YE), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. Expedition-Navigator: If Connector C3265A is damaged at Pin M GD138 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 10356 position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. MKX: If Connector C3036A is damaged at Pin M GD145 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. NOTE IF PIN M IS DAMAGED ON THE MODULE THE DCSM MAY NEED TO BE REPLACED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082311A 2007-2008 MKX: Replace 1.5 Hrs. Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2006 Zephyr, 2007-2008 1.4 Hrs. MKZ: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2007-2008 Expedition, 1.3 Hrs. Navigator: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311B 2006 Zephyr, 2007-2008 1.6 Hrs. MKX And MKZ: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 10357 12650D) 082311B 2007-2008 Expedition, 1.5 Hrs. Navigator: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 14S411 X1 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative Seat Heater: All Technical Service Bulletins A/C - Climate Seat Function Inoperative TSB 08-23-11 11/24/08 INOPERATIVE OR NO COMMUNICATION WITH DUAL CLIMATE CONTROL SEAT MODULE (DCSM) FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 MKZ, MKX, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles may exhibit inoperative climate seat function with no communication to the DCSM due to a ground concern. ACTION Follow service procedure to correct concern. SERVICE PROCEDURE NOTE THIS PROCEDURE ONLY APPLIES IF DAMAGE HAS BEEN IDENTIFIED AT THE SPECIFIC CONNECTOR AND PIN. IF DAMAGE IS NOT VISIBLE AT THE SPECIFIC CONNECTOR AND PIN, THIS PROCEDURE DOES NOT APPLY AND CONTINUE WITH NORMAL DIAGNOSTICS IN THE APPROPRIATE WORKSHOP MANUAL. Refer to Workshop Manual (WSM), Section 501-10 to gain access to the DCSM connector. Seat removal may be required. Zephyr-MKZ: If Connector C3305A is damaged at Pin M GD139 (BK-YE), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. Expedition-Navigator: If Connector C3265A is damaged at Pin M GD138 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 10363 position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. MKX: If Connector C3036A is damaged at Pin M GD145 (BK-WH), then replace connector pigtail. The replacement pigtail will have an extra wire in Pin L position. (Figure 1) 1. Obtain Pigtail Kit. Strip the ends of the wires from Pins L and M, 1/4" (6.3 mm). Twist them together. Insert twisted wires into one end of a 12-10 gage butt splice. Using the approved splicing methods found in the Wiring Diagram (WD), Cell 5, crimp the butt connector. 2. Strip the end of GD139 (vehicle harness side - ground) and insert into open end of the 12-10 butt splice (at Pin M). Using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal with shrink tubing. 3. Continue to attach the rest of the pigtail wires to the vehicle harness, using the approved splicing methods found in the WD, Cell 5, crimp the butt connector and seal (with shrink tubing). Wires from pins E and F will require 12-10 butt splice which is not included in the pigtail kit. NOTE IF PIN M IS DAMAGED ON THE MODULE THE DCSM MAY NEED TO BE REPLACED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082311A 2007-2008 MKX: Replace 1.5 Hrs. Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2006 Zephyr, 2007-2008 1.4 Hrs. MKZ: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311A 2007-2008 Expedition, 1.3 Hrs. Navigator: Replace Connector, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) 082311B 2006 Zephyr, 2007-2008 1.6 Hrs. MKX And MKZ: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 08-23-11 > Nov > 08 > A/C - Climate Seat Function Inoperative > Page 10364 12650D) 082311B 2007-2008 Expedition, 1.5 Hrs. Navigator: Replace Connector And DCSM, Includes Time To Remove And Install Seat (Do Not Use With 63100A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 14S411 X1 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10367 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10368 orientation. 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10369 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10370 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10371 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10372 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10373 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10374 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10375 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10376 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10377 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10378 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10379 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10380 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10381 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10382 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10383 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10384 Seat Heater: Connector Views C3034 C3035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10385 C3039 C3316 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10386 C3040 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10387 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 (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10388 119-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10389 119-3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10390 119-4 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 (2007)) 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 Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10393 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10394 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10395 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10396 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 affected seat backrest fully forward. 2. Depower the supplemental restraint system (SRS). 3. Release the seat backrest cover lower rear J-clip, then unzip the 2 side zippers. 4. Remove the climate controlled seat thermo-electric device (TED). - Disconnect the TED electrical connector. - Remove the scrivet. - Detach the 2 retainer clips from the backrest frame support wires. 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10397 Seat Heater: Service and Repair Seat Cushion Thermo-Electric Device SEAT CUSHION THERMO-ELECTRIC DEVICE Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10398 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10399 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10400 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10401 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat and depower the supplemental restraint system (SRS). 2. NOTE: - Use care when removing the thermo-electric device (TED). The U-nuts can slip into the cushion frame. - Note wiring harness routing for installation. Remove the climate controlled seat thermo-electric device (TED). Disconnect the electrical connector. - Detach the pin-type retainer and wiring harness. - Remove the 2 screws. - Route the wiring harness and remove the TED. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10402 3. To install, reverse the removal procedure. 4. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: Customer Interest A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 10411 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative Seat Heater Control Module: All Technical Service Bulletins A/C - Climate Control Seats Inoperative TSB 07-21-6 10/29/07 CLIMATE CONTROL SEAT FUNCTION INOPERATIVE - NO COMMUNICATION - DCSM VEHICLES BUILT PRIOR TO 8/31/2007 FORD: 2007-2008 Expedition LINCOLN: 2006 Zephyr 2007-2008 KZ, Navigator ISSUE Some 2007-2008 Expedition and Navigator, 2006 Zephyr and 2007-2008 MKZ vehicles built before 8/31/2007 and equipped with climate control seats may exhibit inoperative heating and/or cooling. There are no diagnostic trouble codes (DTCs) associated with this issue and IDS/PDS will not communicate with the dual climate control seat module (DCSM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Turn the ignition switch to key on engine off (KOEO) position. 2. Run self test on DCSM. a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual (WSM) diagnostics for the DTCs. b. If no communication with the DCSM, proceed to Step 3. 3. Remove power to the DCSM and wait a minimum of 2 minutes. This will reset the DCSM. ^ Expedition/Navigator - remove Fuse 8 in the battery junction box (BJB). ^ Zephyr/MKZ - remove Fuse 11 and 12 in the BJB. 4. Reinstall the fuse(s) and recheck for communication. a. If communication does not return, refer to WSM, Section 418-00. b. If the communication is restored by resetting: (1) Expedition/Navigator/2008 MKZ - reprogram the DCSM to the latest calibration using IDS release 51.4 or later with patch 7. Calibration files may also be obtained at the website. (2) 2006 Zephyr/2007 MKZ - replace the DCSM. 5. Recheck operation of the heated/cooled seat and for DTCs. If no DTCs return the vehicle to the customer. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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: > 07-21-6 > Oct > 07 > A/C - Climate Control Seats Inoperative > Page 10417 072106A 2007-2008 0.5 Hr. Expedition/Navigator/2008 MKZ With Climate Control Seats Built Before 8/31/2007: Reprogram The DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D 12651D, 12651D4) 072106A 2006 Zephyr, 2007 MKZ: 1.0 Hr. Replace DCSM, Includes Time For The Diagnosis Described In The Service Procedure (Do Not Use With 12650D, 12651D, 12651D4, 63100A) DEALER CODING CONDITION BASIC PART NO. CODE 14C724 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10418 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10419 Seat Heater Control Module: Diagrams C3265A C3265B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10420 C3265C Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10421 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When installing a new climate control seat module (CCSM), carry out the appropriate steps in the programmable module installation (PMI) procedure. 2. Position the front passenger seat fully upward and depower the supplemental restraint system (SRS). 3. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 4. Release the 2 tabs and slide out the CCSM. 5. Remove the CCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. If a new CCSM has been installed, carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front Seat Heater Switch: Service and Repair Seat Control Switch - Front SEAT CONTROL SWITCH - FRONT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10426 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10427 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10428 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10429 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. All seats 1. Position the seat forward and upward to aid in seat control switch removal. 2. Depower the supplemental restraint system (SRS). 3. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. Power seat with manual recliner 4. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10430 5. Remove the cushion side shield cover forward screw. 6. CAUTION: Do not damage the manual recliner lever when removing the cushion side shield cover. Remove the cushion side shield cover. Partially remove the cover to gain access to the seat control switch. - Release the retainers and detach the seat control switch from the side shield cover. - Remove the cushion side shield cover. All seats 7. Detach and remove the cushion side shield cover. - Disconnect the seat control switch. - If equipped, disconnect the memory set switch electrical connector. 8. Release the clips and remove the seat control switch. 9. To install, reverse the removal procedure. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10431 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. Reach a hand behind the RH rear quarter trim panel and squeeze together the 2 tabs on the affected seat control switch to release. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual Seat Track: Service and Repair Seat Track - Manual SEAT TRACK - MANUAL Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10436 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10437 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10438 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10439 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Remove the inboard and outboard seat track rails. - Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails. To install, tighten to 30 Nm (22 lb-ft). - Remove the inboard and outboard seat track rails. - Release and separate the seat track adjust handle from the seat track rails. - NOTE: Note the spring position for installation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10440 Disconnect the spring. - Slightly bend the tab and detach the seat adjust handle from the inboard seat track rail. 3. To install, reverse the removal procedure. 4. Install the seat. 5. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10441 Seat Track: Service and Repair Seat Track - Power SEAT TRACK - POWER Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10442 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10443 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10444 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10445 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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. Remove the affected seat and depower the supplemental restraint system (SRS). 2. Remove the seat backrest. 3. Remove the safety belt buckle pretensioner. - Remove the tie strap. - Disconnect the 2 electrical connectors. - Remove the nut and safety belt buckle pretensioner. To install, tighten to 55 Nm (41 lb-ft). 4. Release the cushion trim cover front and rear J-clips and rear hook-and-loop strip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10446 Climate controlled seats 5. NOTE: - Use care when removing the thermo-electric device (TED). The U-nuts can slip into the cushion frame. - Note wiring harness routing for installation. Remove the climate controlled seat thermo-electric device (TED). Disconnect the electrical connector. - Detach the pin-type retainer and wiring harness. - Remove the 2 screws. - Route the wiring harness and remove the TED. 6. Release the 2 tabs and slide out the climate controlled seat module (CCSM). 7. NOTE: When installing a new climate control seat module (CCSM), it is necessary to carry out programmable module installation (PMI). If passenger seat, remove the CCSM. Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. Driver memory seat Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 10447 8. Remove the driver seat module (DSM). - Disconnect the 5 electrical connectors. - Release the 2 tabs and slide out the DSM. All seats 9. Remove the cushion frame, foam pad and trim cover assembly from the seat track. - Remove the 4 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion frame. 10. Disconnect the seat track motor electrical connector. - For 6-way power seat, disconnect the 3 motor electrical connectors. - For memory seat, disconnect the 6 motor electrical connectors. 11. NOTE: Note wiring harness routing for installation. Remove the wiring harness. Remove the 3 wiring harness bracket screws. - Remove the tie strap and release the rear wiring harness bracket clip from the seat track. - Separate the electrical connectors and wiring harness from the seat track. - Route and remove the wiring harness and bracket. 12. To install, reverse the removal procedure. 13. Install the seat backrest. 14. Install the seat and repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) 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 (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: Customer Interest Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Customer Interest: > 07-18-5 > Sep > 07 > Electrical - Battery Drain/No Crank/Multiple DTC's > Page 10463 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical Battery Drain/No Crank/Multiple DTC's Pedal Positioning Switch: All Technical Service Bulletins Electrical - Battery Drain/No Crank/Multiple DTC's TSB 07-18-5 09/17/07 BATTERY DRAW AND/OR CRANK/NO START- VEHICLES BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience a battery draw and/or crank/no start concern with these specific diagnostic trouble codes (DTCs) P0230, P0600, P2105, P2107, and U0300 in the PCM. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check for possible internal short at the brake pedal position (BPP) switch. An internal short will not allow the PCM to go into sleep mode. 1. Turn the ignition switch to the off position. Check fuses F70, F74, and F76 in the battery junction box (BJB). Is voltage present on the fuses? a. If yes, go to Step 2. b. If no, this TSB does not apply. Proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) Diagnostics, Pinpoint Test QT1. 2. Disconnect the BPP switch and recheck fuses. Is voltage still present? a. If no, replace the BPP switch and go to Step 3. b. If yes, proceed with normal PC/ED Diagnostics, Pinpoint Test QT1. 3. Start the vehicle. Clear and recheck for DTCs. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Parts Block OPERATION DESCRIPTION TIME 071805A 2007 Expedition/Navigator: 0.4 Hr. Replace The BPP Switch, Includes Time To Perform The Diagnosis In The Service Procedure (Do Not Use With 13480A) DEALER CODING CONDITION BASIC PART NO. CODE 13480 42 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-18-5 > Sep > 07 > Electrical Battery Drain/No Crank/Multiple DTC's > Page 10469 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area Steering Column Bearing: All Technical Service Bulletins Interior - Tick/Creak From Instrument Panel Area TSB 08-17-4 09/01/08 TICKING OR CREAKING SOUND - INSTRUMENT PANEL AREA FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a ticking or creaking sound coming from the instrument panel area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To determine if column lower bearing is source of noise, do the following: 1. Park vehicle on level ground with steering wheel in straight ahead 12 o'clock position and engine off. 2. From underneath instrument panel, grasp lower intermediate shaft U-joint and apply light pressure up and down to load the lower column bearing. 3. Listen for any ticking or creaking sound while applying pressure up and down. 4. If no noise is heard at 12 o'clock wheel position, repeat Step 3 at the 3, 6, and 9 o'clock wheel positions. 5. If noise is detected, use chassis ears to confirm noise is coming from plastic steering column lower bearing. Noise will be loudest with chassis ears attached to the plastic tone ring disc, which is part of bearing. a. If the noise is confirmed go to Step 6. b. If not confirmed this procedure does not apply. Refer to Workshop Manual (WSM), Section 100-04. NOTE COMPLETE DISASSEMBLY OF STEERING COLUMN IS NOT REQUIRED. FOLLOW THE WORKSHOP MANUAL STEPS NECESSARY TO REMOVE ONLY THE LOWER STEERING COLUMN BEARING. 6. Replace steering column lower bearing following WSM, Section 211-04. 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 081704A 2007-2008 Expedition, 1.2 Hrs. Navigator: Replace Steering Column Lower Bearing. Includes Time to Remove and Install Steering column.(Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area > Page 10475 Use With 3514A) DEALER CODING CONDITION BASIC PART NO. CODE 3A510 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pedal Positioning Switch: > 08-17-4 > Sep > 08 > Interior - Tick/Creak From Instrument Panel Area > Page 10481 Use With 3514A) DEALER CODING CONDITION BASIC PART NO. CODE 3A510 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 10482 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 10483 C2089 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 10484 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 10485 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Technical Service Bulletins > Page 10486 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10491 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10494 C605 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10495 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10496 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10497 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Release the tabs and remove the door lock control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10501 C527 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10502 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10503 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10504 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10505 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10510 View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10511 Power Seat Motor Position Sensor: Locations Height Sensor, Left/Right Rear View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front/Rear Height Position Sensor > Page 10512 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10515 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10516 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10517 C4092 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 10518 C4093 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10523 View 151-34 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10524 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left/Right View 151-26 (Right Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Power Seat Switch, Left > Page 10525 View 151-30 (Right Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10528 Power Seat Switch: Diagrams Power Seat Switch, Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10529 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 10530 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10533 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10534 Power Seat Switch: Testing and Inspection Power Seat Switch, 6-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10535 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10536 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10537 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10538 Power Seat Switch: Testing and Inspection Power Seat Switch, 10-Way Power Seat - Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10539 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10540 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10541 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10542 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10543 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10544 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10545 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10546 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10547 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10548 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10549 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10550 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, 6-Way Power Seat - Left > Page 10551 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 10552 Power Seat Switch: Service and Repair MEMORY SET SWITCH Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 10553 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 10554 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 10555 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 10556 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. 1. Depower the supplemental restraint system (SRS). 2. Detach and position aside the driver seat cushion side shield cover. 3. Release the clips and remove the memory set switch. - Disconnect the seat control switch. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair Power Trunk / Liftgate Hazard Sensor: Service and Repair PINCH STRIP SWITCH Removal and Installation NOTE: Left side shown, right side similar. 1. Remove brake light. - Remove the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Page 10560 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1 Remove the pin-type retainers. 2 Remove the grommet and route the harness out of the vehicle. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-41 (Liftgate - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch C4340 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 10566 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the outboard side of the driver 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 (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front Seat Heater Switch: Service and Repair Seat Control Switch - Front SEAT CONTROL SWITCH - FRONT Seat Backrest - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10574 Seat Backrest - Front, 40 Percent (Part 2) Seat Cushion - Front, 40 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10575 Seat Cushion - Front, 40 Percent (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10576 Seat Cushion - Front, 60 Percent (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10577 Seat Cushion - Front, 60 Percent (Part 2) Exploded View 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 shown, passenger similar. All seats 1. Position the seat forward and upward to aid in seat control switch removal. 2. Depower the supplemental restraint system (SRS). 3. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. Power seat with manual recliner 4. CAUTION: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10578 5. Remove the cushion side shield cover forward screw. 6. CAUTION: Do not damage the manual recliner lever when removing the cushion side shield cover. Remove the cushion side shield cover. Partially remove the cover to gain access to the seat control switch. - Release the retainers and detach the seat control switch from the side shield cover. - Remove the cushion side shield cover. All seats 7. Detach and remove the cushion side shield cover. - Disconnect the seat control switch. - If equipped, disconnect the memory set switch electrical connector. 8. Release the clips and remove the seat control switch. 9. To install, reverse the removal procedure. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat Control Switch - Front > Page 10579 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. Reach a hand behind the RH rear quarter trim panel and squeeze together the 2 tabs on the affected seat control switch to release. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-33 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 10583 C3246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch View 151-25 (Left Rear - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 10588 View 151-29 (Left Rear - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 10589 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch C4333 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 10592 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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. To install, reverse the removal procedure. 6. If necessary, adjust the windshield wiper arms. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area Front Door Weatherstrip: Customer Interest Body - Wind Noise From Front Door B-Pillar Area TSB 07-13-4 07/09/07 WIND NOISE AROUND FRONT DOORS - BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-8-6 to clarify vehicle build date. ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience wind noise around the exterior driver and/or passenger doors. This may be most noticeable near the b-pillar area of the door. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE VEHICLE IS BUILT AFTER 12/6/2006, THIS TSB DOES NOT APPLY. PROCEED WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS, REFER TO WORKSHOP MANUAL (WSM), SECTION 100-04. 1. Check the build date of the vehicle. a. If the build date of the vehicle is before 12/1/2006, continue to Step 2. b. If the build date of the vehicle is between 12/1/06 and 12/6/06, continue to Step 3. 2. Verify that the glass run inserts at the b-pillar corner are still in the correct position. (Figure 1) a. First roll down the window and peel back the inner flocked sealing lip in the b-pillar corner. b. There will be two inserts located in the corner. They should both be touching in the corner and at a 90 degree angle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 10610 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body - Wind Noise From Front Door B-Pillar Area > Page 10611 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body Wind Noise From Front Door B-Pillar Area Front Door Weatherstrip: All Technical Service Bulletins Body - Wind Noise From Front Door B-Pillar Area TSB 07-13-4 07/09/07 WIND NOISE AROUND FRONT DOORS - BUILT BEFORE 1216/2006 FORD: 2007 Expedition LINCOLN: 2007 Navigator This article supersedes TSB 07-8-6 to clarify vehicle build date. ISSUE Some 2007 Expedition and Navigator vehicles built before 12/6/2006 may experience wind noise around the exterior driver and/or passenger doors. This may be most noticeable near the b-pillar area of the door. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE VEHICLE IS BUILT AFTER 12/6/2006, THIS TSB DOES NOT APPLY. PROCEED WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS, REFER TO WORKSHOP MANUAL (WSM), SECTION 100-04. 1. Check the build date of the vehicle. a. If the build date of the vehicle is before 12/1/2006, continue to Step 2. b. If the build date of the vehicle is between 12/1/06 and 12/6/06, continue to Step 3. 2. Verify that the glass run inserts at the b-pillar corner are still in the correct position. (Figure 1) a. First roll down the window and peel back the inner flocked sealing lip in the b-pillar corner. b. There will be two inserts located in the corner. They should both be touching in the corner and at a 90 degree angle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body Wind Noise From Front Door B-Pillar Area > Page 10617 c. Sometimes they can shift or fall down into the channel. After verifying the correct plug position, continue to Step 3. NOTE SOME TRUCKS BUILT DURING THE MONTH OF NOVEMBER MAY NOT HAVE THE TWO INSERTS MENTIONED IN FIGURE 1, THERE MAY BE A SINGLE MOLDED PLUG INSTEAD. IF THERE IS A SINGLE MOLDED PLUG AS SHOWN IN FIGURE 1, CONTINUE TO STEP 3. 3. With the front door window in the up position, inspect the b-pillar metal carrier for being slightly bowed out and not making contact to the outside glass surface. (Figure 2) a. To adjust, compress the b-pillar metal carrier inward just below the b-pillar corner to ensure it seals to the glass. This can be done by rolling the window down and pressing inward in the location mentioned above. NOTE BE CAREFUL NOT TO OVER COMPRESS THE METAL B-PILLAR CARRIER. b. Continue to Step 4. 4. Next, with the window in the up position, Inspect the front glass run for any gaps by running a piece of paper between the glass run and window to Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 07-13-4 > Jul > 07 > Body Wind Noise From Front Door B-Pillar Area > Page 10618 determine any areas where sealing may be an issue. (Figure 3) a. Make sure to run the paper along both the inside and outside sealing sur[aces of the window to glass run inter[ace. b. If a piece of paper freely slips between the glass run and the window at any location then there may be a sealing issue and the glass run needs to be replaced. NOTE IF THE WIND NOISE CONCERN IS STILL PRESENT AFTER PERFORMING THIS SERVICE PROCEDURE, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSIS, REFER TO WSM, SECTION 100-04. 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 071304A 2007 Expedition/Navigator: 0.9 Hr. Replace The Glass Run, Includes Time To Follow Service Procedure: One Door (23943A, 23943A14, 21 596A) 071304B 2007 Expedition/Navigator: 1.7 Hrs. Replace The Glass Run, Includes Time To Follow Service Procedure: Both Doors (23943A, 23943A14 21596A) DEALER CODING CONDITION BASIC PART NO. CODE 7821546/7821547 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-FRONT Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10622 Exploded View 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 (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-REAR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10626 Part 2 Exploded View 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 (2007)) 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 (2007)) 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 10635 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 (2007)) 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 10636 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 (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Sunroof / Moonroof Weatherstrip: Customer Interest Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 10641 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 10647 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 (2007)) 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 10648 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 (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Interior - Gap Between Headliner and Sunroof Panel TSB 07-22-3 11/12/07 GAP/FIT - HEADLINER TO ROOF OPENING PANEL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles equipped with a roof opening panel may experience customer concerns with the fit/gap between the headliner and roof opening panel. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Check the fit of the roof opening panel to headliner (Figure 1). a. If there is a gap or poor fit between roof opening panel and headliner or the roof opening panel is not covering all the outlying areas of the headliner, go to Step 2. b. If no gap is present, this TSB does not apply, follow Workshop Manual, Section 501-17. 2. Use a sofi pick or equivalent to lift the roof opening panel weatherstrip over the headliner. 3. Finesse and smooth the headliner material to the backing of the headliner if needed. 4. Reposition, finesse and smooth the roof opening panel weatherstrip so it covers the gap or poor fit area of the headliner. The glue that is on the headliner backing will then adhere to the headliner material keeping it in place and the repositioning of the weatherstrip will repair the concern. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072203A 2007-2008 0.2 Hr. Expedition/Navigator: Follow The Service Procedure To Correct The Condition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-22-3 > Nov > 07 > Interior - Gap Between Headliner and Sunroof Panel > Page 10653 DEALER CODING CONDITION BASIC PART NO. CODE 7852124 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10654 Sunroof / Moonroof Weatherstrip: Service and Repair ROOF OPENING PANEL WEATHERSTRIP Exploded View 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10655 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 (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10660 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 10663 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 (DTC) is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 10670 Navigator Removal and Installation Expedition NOTE: It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10675 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10678 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 (DTC) is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 10685 Navigator Removal and Installation Expedition NOTE: It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams C4186 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 orientation. 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 C2031 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 44-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams C2016 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 10718 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 (2007)) 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. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10721 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10722 Clock: Pinpoint Tests PINPOINT TESTS A: THE CLOCK OPERATION IS INOPERATIVE A1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10723 A1-A3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10724 A4 Normal Operation The clock receives battery voltage from the smart junction box (SJB) through circuit SBP14 (BN/RD). Ground for the clock is supplied through circuit GD138 (BK/WH). Possible Causes - Fuse - Circuit SBP14 (BN/RD) open - Circuit GD138 (BK/WH) open - Clock - SJB Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 10725 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 10726 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams C909 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center Compass: Service and Repair Compass Zone Adjustment - With Message Center COMPASS ZONE ADJUSTMENT - WITH MESSAGE CENTER 1. Determine which magnetic zone you are in for your geographic location. 2. Start the engine. 3. Press the message center SETUP button until RESET FOR ZONE SETTING is displayed. 4. Press and release the RESET button until ZONE XX RESET = CHANGE is displayed. 5. NOTE: The zone selection increases with each subsequent button press with a range of zones from 1 to 15 scrolling back to the beginning. Press and release the RESET button until the desired zone appears in the message center display. 6. To exit the zone setting mode and lock in the changes, press and release either the RESET or SETUP button or simply wait 4 seconds and the message center locks in the zone. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 10732 Compass: Service and Repair Compass Zone Adjustment - Without Message Center COMPASS ZONE ADJUSTMENT - WITHOUT MESSAGE CENTER 1. Determine which magnetic zone you are in for your geographic location. 2. Start the engine. 3. Locate the reset button on the top of the compass module at the base of the interior rear view mirror. 4. Press and hold the reset button for 6 seconds and release when ZONE appears in the instrument cluster display. 5. NOTE: The zone selection increases with each subsequent button press with a range of zones from 1 to 15 scrolling back to the beginning. Press and release the reset button until the desired zone number appears. 6. When the desired zone number appears in the instrument cluster display, do not press the reset button. The instrument cluster locks in the zone setting and returns to normal operation when the reset button is not pressed for approximately 4 seconds. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 10733 Compass: Service and Repair Compass Calibration - With Message Center COMPASS CALIBRATION - WITH MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater, A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Press the message center SETUP button until RESET FOR CALIBRATION is displayed. 3. NOTE: The message center displays CIRCLE SLOWLY TO CALIBRATE in the calibration function. Press the RESET control button to start the compass calibration function. 4. NOTE: - This step may require up to 5 circles to complete the calibration. - If the RESET button is pressed during the calibration or 3 minutes has elapsed since the beginning of the calibration without driving the vehicle, the message center reverts back to normal operation and the INFO displays CAL until a successful calibration is carried out. Slowly drive the vehicle in a circle less than 5 km/h (3 mph) until the CIRCLE SLOWLY TO CALIBRATE display changes to CALIBRATION COMPLETED. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 10734 Compass: Service and Repair Compass Calibration - Without Message Center COMPASS CALIBRATION - WITHOUT MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater, A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Locate the reset button on the top of the compass module at the base of the interior rear view mirror. 3. Press and hold the reset button for 8 seconds and release when CAL appears in the instrument cluster display. 4. NOTE: This step may require up to 5 circles to complete the calibration. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CAL turns off in the instrument cluster display. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10740 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10741 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10742 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10743 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10744 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10745 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10746 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10747 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10748 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10749 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10750 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10751 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10752 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 10757 Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 10758 Vehicles with power tilt 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 10763 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 10764 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 10765 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10768 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10769 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10770 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Driver/Vehicle Information Display: Customer Interest Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 10779 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 10780 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors Driver/Vehicle Information Display: All Technical Service Bulletins Instruments - Message Center Switches Inop/Other Errors TSB 07-7-4 04/16/07 MESSAGE CENTER SWITCHES INOP-TEXT BLANK/SCRAMBLED/COMPASS INOP/WASHER LIGHT ON/OAT READS HIGH FORD: 2007 Expedition LINCOLN: 2007 Navigator ISSUE Some 2007 Expedition and Navigator vehicles built before 12/22/2006 may exhibit concerns with the Instrument Cluster (IC). The outside air temp reads 140 °F (60 °C), message center switches unresponsive/text blank or scrambled, compass display is inoperative, washer fluid level light is on. ACTION Follow the Service Procedure steps to correct the condition. NOTE DO NOT REPLACE IC ASSEMBLY UNTIL COMPLETE DIAGNOSIS HAS BEEN PERFORMED. SERVICE PROCEDURE Check the build date code of the IC. The date code is displayed in the message center during "engineering test mod&'. Engineering Test Mode: 1. Ignition in "OFF" position. 2. Cluster type. a. For Base Clusters (without message center cluster): depress the reset stem on the cluster while turning the ignition switch to the "ON" position. b. Message Center Clusters: depress the reset button in the vehicle while turning the ignition switch to the "ON" position. 3. Continue to hold down the reset stem/button for 5 seconds until the cluster message center displays "engineering test mode". 4. Press/cycle reset stem/button until the message center displays "manufacture" and the date of manufacture (MM-DD-YYYY). 5. If the date is after 12/22/2006, this TSB does not apply and proceed with normal diagnostics found in Workshop Manual (WSM), Sections 413-01 and 413-08. 6. Turn the vehicle ignition to the "OFF" position to exit the "engineering test mode". Outside Air Temperature (OAT) Diagnostics NOTE THIS PROCEDURE IS FOR VEHICLES WITHOUT (ELECTRONIC AUTOMATIC TEMPERATURE CONTROL) EATC. 1. Run vehicle for 5 minutes. 2. Verify the OAT reads 140 °F (60 °C) in the Message Center. 3. Disconnect the OAT sensor. 4. Does the Message Center still read 140 °F (60 °C)? a. Yes - proceed to Step 4. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 10786 b. No - follow WSM, Section 413-08. 5. Disconnect battery. 6. Disconnect IC. 7. Measure the resistance between pins 1 and 2 on Connector C132. a. Resistance less than 1 Meg-Ohms - Repair shorted circuits. b. Resistance greater than 1 Meg-Ohms - Proceed to Step 8. 8. Reconnect IC and OAT sensor. 9. Reconnect battery, to verify IC connection. If Message Center still reads 140 °F (60 °C), replace IC. Message Center (MC) Switch, Diagnostics: Refer to WSM, Section 413-08 Pinpoint Test B: The Message Center Switch Does Not Operate Correctly Low Washer Fluid Level Light On, Diagnostics 1. Verify low washer fluid level light is on and washer bottle is full. 2. Verify washer fluid level switch is fully seated in the bottle. Is light still on? a. No - repair is complete. b. Yes - proceed to Step 3. 3. Disconnect the washer fluid level switch. Does the light go out after one minute? a. Yes - proceed with normal WSM, Section 413-01 Diagnostics. b. No - proceed to Step 4. 4. Disconnect battery. 5. Disconnect IC. 6. Measure the resistance on Pins 1 and 2 of Connector C138. Is the resistance less than 1 Meg-Ohms? a. Yes - repair shorted wires. b. No - proceed to step 7. 7. Reconnect the washer fluid level switch, IC and then battery to verify IC connections. If light is still on, replace the IC. No Compass Display Diagnostics Refer to WSM Section 413-08 Pinpoint Test C: The Compass Is Inoperative. Message Center Display Blank/Text Scrambled, Diagnostics Refer to WSM Section 413-08 Symptom Chart 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 MT070704 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 07-7-4 > Apr > 07 > Instruments - Message Center Switches Inop/Other Errors > Page 10787 DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10788 View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10789 C253 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10790 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green (Expedition) items or white (Navigator) vacuum fluorescent, fixed units format, 2-line display integrated into the center of enable/ the instrument cluster and is controlled by the entry/ message center switches. There are two basic equipped), instrument cluster/message center configurations. items The first is the full function message center and can in be identified by the three button message center approximately switch located in the instrument panel center finish The panel. The second is the base cluster message decrease center and can be identified by the single reset can button located in the instrument cluster. Both approximately instrument cluster configurations display messages was based upon vehicle option content. The base cluster message center functions and menus listed below can be selected through the reset button by pressing and releasing the reset button to scroll through the menu items. The INFO items (trip A, trip B and average fuel economy) can be reset by holding the reset button for approximately 2 seconds. The SETUP items, (language, system configurable items [autolamps, autolock, auto unlock etc.]) can be reset by holding the reset button for approximately 2 seconds when the selected menu item is displayed. Refer to the Owner's Literature for complete operating instructions for both the full function message center and the base instrument cluster message center. The message center provides the following features: - Information displays - Setup displays - System check messages - System warning messages The full function message center features and menus listed below can be selected through a set of 3 buttons: - INFO - SETUP - RESET Message Center Configuration The message center has the capability to configure items such as oil life, oil life start value, language, units (English or metric), autolamp delay, to enable/disable a variety of options such as easy entry/easy exit (if equipped) and air suspension (if equipped), or to carry out calibrations/settings on items such as the compass. The oil life is displayed in percent and is preset to a maximum of approximately 8,000 km (5,000 miles) or 180 days. The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% decrements down to 10%. On configurable items such as parking aid on/off and air suspension on/off (if equipped) the message center indicates the appropriate selection (ON/OFF) by bracketing the selection. An example is as follows: PARKING AID OFF. The parking aid is enabled or on in the previous example. If the driver selects the parking aid off, the display would be: PARKING AID ON . Reconfigurable Telltale Indicators The message center displays reconfigurable telltale indicators in the RH side of the display area. Reconfigurable telltale indicators replace indicators that have been typically displayed in the instrument cluster and use the same iconic representation. Compass and Outside Air Temperature Displays The message center provides a compass display and uses directional information sent from a compass module, located on the underside of the inside rear view mirror. The message center provides an outside air temperature display on vehicles that are not equipped with electronic automatic temperature control (EATC). 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 - Outside air temperature display (if equipped) - Compass - Distance to empty (DTE) - Average fuel economy - Instantaneous fuel economy - Blank display Setup Displays The setup displays are timed modes and terminate after a finite interval.The setup display modes are: Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10791 - System check - Oil life - Units English/metric - Autolamp delay in seconds (if equipped) - Easy entry/easy exit seat on/off (if equipped) - Air suspension on/off (if equipped) - Autolocks on/off (if equipped) - Power liftgate on/off (if equipped) - Power running boards auto/off/out (if equipped) - Compass zone - Compass calibration - Language System Check The system check provides a check of all the monitored systems on the vehicle. The system check scrolls through each of the monitored systems and provides a visual indication to report out the status of each system. The message center displays OK for approximately 2 seconds if the system check does not detect a fault in the system and displays a warning message for approximately 2 seconds if the system check detects a fault in the system. Press the RESET button to scroll through the system check messages. The system check messages are: OIL LIFE - CHARGING SYSTEM - WASHER FLUID LOW - DOOR STATUS - LIFTGATE/GLASS - BRAKE FLUID LEVEL - TIRE PRESSURE SYSTEM (if equipped) - AIR SUSPENSION SYSTEM (if equipped) - FUEL LEVEL System Warning Messages The system warning messages alert the operator to possible problems or malfunctions in the vehicle operating systems. The message center displays the last selected feature if there are no additional warning messages. Once a warning message has been displayed, the message must be acknowledged to allow full functionality of the message center. Press the RESET to acknowledge and clear the warning message. The warning messages are divided into 4 categories: - Cannot be cleared until the condition is corrected. - Reappear on the display 10 minutes from the reset if the condition has not been corrected. - Do not reappear until an ignition OFF-ON cycle has been completed. - Reappear if the condition clears then reoccurs within the same ignition cycle ON-OFF cycle. The warning display that cannot be reset is: PARK AID ON/OFF The warning messages that reoccur after 10 minutes are: CHECK BRAKE SYSTEM - XXX MILES (km) TO E FUEL LOW - PARK BRAKE ENGAGED The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: BRAKE FLUID LEVEL LOW - CHECK PARK BRAKE - WASHER FLUID LEVEL LOW - OIL CHANGE REQUIRED - XXX% OIL LIFE CHANGE SOON - CHECK AIR SUSPENSION SYSTEM (if equipped) The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: DRIVER DOOR AJAR - PASSENGER DOOR AJAR - REAR LEFT DOOR AJAR - REAR RIGHT DOOR AJAR - LIFTGATE/GLASS AJAR - CHECK CHARGING SYSTEM - TIRE PRESSURE SENSOR FAULT (if equipped) - LOW TIRE PRESSURE (if equipped) - TIRE PRESSURE MONITOR FAULT (if equipped) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10792 - 4X4 SHIFT IN PROGRESS (if equipped) - AIR SUSPENSION OFF (if equipped) The message center displays warning messages that indicate a system state during the operation of the four wheel drive (4WD) system (late build only). The displayed warning messages are as follows: FOR 4X4 STOP VEHICLE (if equipped) - FOR 4X4 LOW APPLY BRAKE (if equipped) - FOR 4X4 LOW SHIFT TO N (if equipped) - TO EXIT 4X4 LOW STOP VEHICLE (if equipped) - TO EXIT 4X4 LOW APPLY BRAKE (if equipped) - TO EXIT 4X4 LOW SHIFT TO N (if equipped) The message center displays warning messages that indicate a system state during repair procedures related to the tire pressure monitoring system (TPMS). The displayed warning messages are as follows: TRAIN LEFT TIRE (if equipped) - TRAIN LEFT REAR TIRE (if equipped) - TRAIN RIGHT FRONT TIRE (if equipped) - TRAIN RIGHT REAR TIRE (if equipped) - TRAIN SPARE TIRE (if equipped) - TRAINING COMPLETE (if equipped) - TIRES NOT TRAINED-REPEAT (if equipped) The message center displays warning messages that indicate a system state during repair procedures related to the compass display. The displayed warning messages are as follows: RESET FOR ZONE SETTING - ZONE XX RESET = CHANGE - RESET FOR CALIBRATION - CIRCLE SLOWLY TO CALIBRATE - CALIBRATION COMPLETED - COMPASS DATA ERROR The message center displays warning messages that indicate a system state during repair procedures related to the oil life and oil life start value. The displayed warning messages are as follows: OIL LIFE XXX% HOLD RESET = NEW - OIL LIFE SET TO XXX% Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test: - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center is an integral part of the instrument cluster that receives and acts upon much of the same information that is input and used to operate the instrument cluster gauges, indicators, warning indicators and reconfigurable telltale indicators. The message center, located in the center of the instrument cluster is a vacuum fluorescent 2-line display. The message center electronic functions use both hardwired, and the controller area network (CAN) circuitry to transmit and receive information. Whenever conditions are present that require a warning message, the message center replaces the last selected display with the new warning display. Once the message is reset or cleared, the message center returns to the last selected display. If multiple warnings are present, the message center displays each warning for approximately 4 seconds. Warning messages are also generally associated with other observable instrument cluster indications. For example, when the LH front door is opened, the message center displays the message DRIVER DOOR AJAR along with the door ajar reconfigurable telltale indicator. This allows the message center to be a more informative supplement to the instrument cluster gauges and indicators. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10795 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. Instrument Cluster Messages NOTE: Whenever a message is suspected as missing, confirmed by a missing message DTC, it is important to look for other symptoms that may also be present in the instrument cluster and throughout the vehicle. Once a DTC is set in the instrument cluster it may be helpful to review the complete message list available in Information Bus (Module Communications Network) to see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also be set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems. The instrument cluster uses input messages from other modules to control the gauges, informational indicators, warning indicators and reconfigurable telltale indicators over the communication networks. If a required message is missing or invalid for less than 5 seconds, the gauge or indicator that requires the message remains at the last commanded state based upon the last known good message. For example, if the message is missing the O/D off status for less than 5 seconds and the O/D off indicator was ON (O/D cancelled), the indicator remains in the ON state until the next good message is received. If the message remains missing or invalid for greater than 5 seconds, the instrument cluster sets a U-code DTC and the output becomes a default action for the indicator or gauge. Each indicator or gauge utilizes a different default strategy depending on the nature of the indication. Refer Instrument Panel, Gauges and Warning Indicators. for further descriptions of the default action specific to each indicator or gauge. If the messaged input to the cluster returns at any time, the normal function of the gauge or indicator resumes. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10796 B1255-B2097 / U2013 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10797 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10798 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10799 Symptom Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10800 Symptom Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10801 Symptom Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10802 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 is located in the center of the instrument cluster between the tachometer and the speedometer in the vacuum fluorescent display area. The message center is integral to the instrument cluster and uses the same voltage supply as the instrument cluster. The RUN/START voltage is supplied to the instrument cluster on circuit CBP29 (WH/VT) and the keep alive B+ voltage is received on circuit SBP26 (YE/RD). The instrument cluster ground is received through circuit GD133 (BK). The message center functionality is controlled through the message center switches, which are hardwired to the instrument cluster through the input circuit CMC29 (GN/VT) and the return circuit VMC29 (YE). Possible Causes - Message center switches - Instrument cluster Test B: The Message Center Switch Does Not Operate Correctly PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY B1-B2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10803 B2-B4 Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster through the input circuit CMC29 (GN/VT) and the return circuit VMC29 (YE). There are 3 message center switch buttons with each button operating a switch that uses different resistance values. The instrument cluster sends out a reference voltage to the message center switch on the input circuit and monitors the input voltage when a message center switch button is pressed. The input voltage will vary depending upon the resistance of each button, providing a specific indication to the instrument cluster which switch is pressed. Possible Causes - Circuit CMC29 (GN/VT) open or short to ground - Circuit VMC29 (YE) open or short to ground Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10804 - Message center switch - Instrument cluster Test C: The Compass Is Inoperative PINPOINT TEST C: THE COMPASS IS INOPERATIVE C1-C3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10805 C3-C4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10806 C5 Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP31 (BU/OG) and is grounded through circuit GD133 (BK). The compass sensor module communicates the vehicle direction to the instrument cluster through the compass communication data plus circuit VMC31 (YE/GN) and compass communication data minus circuit VMC30 (BU/GY). DTC B2097 - sets in continuous memory if the instrument cluster detects invalid data sent from the compass module. DTC U2013 - is a continuous memory and on-demand DTC that sets if the instrument cluster is missing the compass data from the compass module. If the instrument cluster fails to receive the compass data, the instrument cluster sets DTC U2013 and defaults the compass display to (----). Possible Causes - Fuse - Circuit CBP31 (BU/OG) open - Circuit GD133 (BK) open - Circuit VMC30 (BU/GY) open or short to ground - Circuit VMC31 (YE/GN) open or short to ground - Compass sensor module Test D: The Compass Is Inaccurate PINPOINT TEST D: THE COMPASS IS INACCURATE D1 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster through the compass communication data plus circuit Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10807 VMC31 (YE/GN) and compass communication data minus circuit VMC30 (BU/GY). The magnetic fields generated by the earths north and south poles are divided into zones that differ from each other with respect to how the magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and become noticeable across multiple zones. The compass zone must be set to the correct zone for the compass to read accurately. Factors within the vehicle may affect the ability of the compass module to accurately read the magnetic north. Calibrating the compass allows the compass module to compensate for vehicle factors that influence the accuracy of the compass. NOTE: Outside factors such as bridges, steel structures, tall buildings and power lines also affect compass accuracy. Possible Causes - Compass sensor module - Zone setting - Calibration Test E: The Outside Air Temperature Sensor Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE SENSOR DOES NOT OPERATE CORRECTLY E1-E4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10808 E4-E5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10809 E6-E7 Normal Operation The outside air temperature sensor is mounted on the radiator core support in front of the radiator and A/C condenser and is hardwired to the instrument cluster through input circuit VH407 (YE/GN) and return circuit VMC29 (YE). The instrument cluster provides a reference voltage to the ambient air temperature sensor and monitors the change in voltage resulting from changes in resistance as determined by outside air temperature. When the engine has been off for 2 hours, or the engine temperature is cold, the instrument cluster displays the current outside air temperature as measured by the ambient air temperature sensor. When the time is less than 2 hours, or if the engine is not cold, the instrument cluster takes a reading of the current temperature and compares the current reading against the last reading at key off. If the temperature is less than the last key off temperature reading, the instrument cluster displays the current temperature. If the temperature is greater than the last key off temperature reading, the instrument cluster displays the last key off temperature reading until the ambient air temperature has had time to stabilize with vehicle movement. DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an open on the outside air temperature sensor input, circuit VH407 (YE/GN). If the instrument cluster detects an open on the outside air temperature input, the instrument cluster defaults the display to 23.89°C (75°F). DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short to ground on the outside air temperature sensor input, circuit VH407 (YE/GN). If the instrument cluster detects a short to ground on the outside air temperature input, the instrument cluster defaults the display to 23.89°C (75°F). Possible Causes - Circuit RH111 (GY/BU) open - Circuit VH407 (YE/GN) open, short to voltage or ground - Circuit VMC29 (YE) open or short to voltage - Outside air temperature sensor - Instrument cluster Test F: The Parking Aid On/Off Warning Is Inoperative PINPOINT TEST F: THE PARKING AID ON/OFF WARNING IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10810 F1-F5 Normal Operation The parking aid on/off status is sent from the parking aid module to the instrument cluster over the medium speed controller area network (MS-CAN) communication bus lines. When the RESET button is pressed, the instrument cluster sends a query to the parking aid module, requesting a system status. The parking aid module responds to the instrument cluster with the status of the system, either on or off. If the return status message is missing or corrupted, the instrument cluster does not display the brackets around either the ON or OFF selection. Possible Causes - Instrument cluster configuration - Parking aid system - Instrument cluster Test G: The Check Air Suspension or Air Suspension Off Warning Is Inoperative PINPOINT TEST G: THE CHECK AIR SUSPENSION OR AIR SUSPENSION OFF WARNING IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10811 G1-G3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10812 G4-G6 Normal Operation The air suspension on/off status is sent from the air suspension module to the instrument cluster over the high speed controller area network (HS-CAN) communication bus lines. When the RESET button is pressed, the instrument cluster sends a query to the air suspension module, requesting a system status. The air suspension module responds to the instrument cluster with the status of the system, either on or off. If the return status message is missing or corrupted, the instrument cluster does not display the brackets around either the ON or OFF selection. Possible Causes - Instrument cluster configuration - Air suspension system - Air suspension module - Instrument cluster Test H: The 4X4 Shift In Progress Warning Is Inoperative PINPOINT TEST H: THE 4X4 SHIFT IN PROGRESS WARNING IS INOPERATIVE H1-H4 Normal Operation The four wheel drive (4WD) control module sends the instrument cluster a message over the high speed controller area network (HS-CAN) communication bus lines when the 4WD system is in the process of shifting out of two wheel drive (2WD) and has not yet fully shifted into 4x4 high, 4x4 low or 4x4 auto. Once the shift is completed, the 4WD control module removes the 4x4 shift in progress message and sends a new message to turn on the applicable reconfigurable telltale indicator. Possible Causes - Instrument cluster configuration - 4WD system - 4WD control module - Instrument cluster Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Oil Life Reset - Message Center Cluster OIL LIFE RESET - MESSAGE CENTER CLUSTER NOTE: - The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE =80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster OIL LIFE RESET - BASE INSTRUMENT CLUSTER NOTE: - All message center functions are carried out using the single stem reset button in the instrument cluster. - The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster OIL LIFE START VALUE - MESSAGE CENTER CLUSTER NOTE: - The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. - The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER NOTE: - All message center functions are carried out using the single stem reset button in the instrument cluster. - The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10815 Driver/Vehicle Information Display: Removal and Replacement MESSAGE CENTER SWITCH Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10816 Removal and Installation Expedition 1. Pull the instrument panel center finish panel straight out to release the retaining clips. Navigator 2. NOTE: The transmission selector lever bezel is held in place by 4 tabs that are located in the shifter assembly. Remove the transmission selector lever bezel. 3. Open the floor console compartment door and pull the floor console finish panel straight up to release the retainer clips. 4. Remove the 2 screws and pull the instrument panel center finish panel straight out to release the retainer clips. - Position the instrument panel center finish panel aside. All vehicles 5. Disconnect the electrical connectors. 6. Press the 4 retaining tabs and remove the message center switch from the center instrument panel finish panel. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 10817 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge: Customer Interest Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10829 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10835 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10838 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10839 orientation. 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10840 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10841 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10842 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10843 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10844 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10845 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10846 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10847 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10848 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10849 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10850 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10851 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10852 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10853 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10854 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System Lower Than Expected Fuel Fill Capacity > Page 10863 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10868 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 10874 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10879 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10880 Fuel Gauge Sender: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10881 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10882 C433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10883 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10884 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10885 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10886 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition switch to 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure 1. Make sure that all supplemental restraint system (SRS) components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install restraints control module (RCM) fuse 32 (10A) to the SPDJB 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.Failure to follow these instructions may increase the risk of personal injury or death in a crash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10892 Connect the battery ground cable. 5. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off.If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10893 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) 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 deployment, which can result in personal injury. - 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON.This is normal operation and does not indicate a 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 smart power distribution junction box (SPDJB), located in the RH lower kick panel, remove the cover and the restraints control module (RCM) fuse 32 (10A) from the SPDJB. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds.The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed.If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition 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, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the bottom of the radiator support bracket. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10894 auxiliary batteries and power supplies (if equipped).Failure to follow these instructions may increase the risk of personal injury or death in a crash. Disconnect the battery ground cable and wait at least one minute. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column. 9. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). Vehicles with manual tilt wheel 10. Remove the lower steering column opening cover. - Remove the 3 screws and pull out to release the top retaining clips and remove the lower steering column opening cover. 11. Remove the screw and steering column manual tilt lever. All vehicles 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10895 15. CAUTION: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.Failure to do so will damage the driver air bag module and steering wheel. NOTE: Steering wheel is removed for clarity.The rear of the steering wheel is shown. - Use a mirror to look at the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. - Note the position of the 2 driver air bag module locator pins to the steering wheel for installation. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. 16. Disconnect the 2 driver air bag module electrical connectors, then disconnect the horn switch electrical connector and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door. - If equipped, disconnect the glove compartment door dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10896 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat.The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical connector. 21. Release the passenger side second row safety belt retractor D-ring cover. 22. Remove the bolt and the passenger side second row safety belt retractor D-ring. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10897 23. Remove the cover and the passenger side C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the passenger side C-pillar trim panel. 25. Disconnect the passenger side safety canopy module electrical connector. 26. Release the driver side second row safety belt retractor D-ring cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10898 27. Remove the bolt and the driver side second row safety belt retractor D-ring. 28. Remove the cover and the driver side C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver side C-pillar trim panel. 30. Disconnect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10899 31. NOTE: There are 2 similar connectors under the driver seat.The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the SPDJB. 33. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 32 (10A) from the SPDJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Connect the driver seat side air bag module electrical connector and install the driver front seat cushion panel shield. 4. Connect the driver side safety canopy module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10900 5. Install the driver side C-pillar trim panel and attach the rear door weatherstrip. 6. Install the driver side C-pillar trim panel nut and cover. 7. Install the driver side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the driver side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10901 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger side C-pillar trim panel nut and cover. 12. Install the passenger side second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10902 13. Attach the passenger side second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. 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 horn switch electrical connector, then connect the 2 driver air bag module electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10903 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: - Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. - Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. Vehicles with manual tilt wheel 23. Install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. Install the lower steering column opening cover and the 3 screws. All vehicles 25. Turn the ignition switch from OFF to ON. 26. Install the RCM fuse 32 (10A) to the SPDJB and install the cover. 27. 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. 28. Prove out the 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 warning indicator with the air bag modules installed.The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 10904 The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position.This is the time required for the RCM to complete the testing of the SRS.If the air bag warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.If this occurs, the air bag warning indicator will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS 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. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out the following procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire (as necessary). 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions: 1. 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 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB 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 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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) 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. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 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. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 CHANGE OIL SOON/OIL CHANGE REQUIRED Displayed when the engine oil life remaining is 5 percent or less. When oil life left is between 5% and 0%, the CHANGE OIL SOON message will be displayed. When oil life left reaches 0%, the OIL CHANGE REQUIRED message will be displayed. An oil change is required whenever indicated by the message center and according to the recommended maintenance schedule. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Press and release the SETUP control to display "OIL LIFE=XXX% HOLD RESET=NEW ". 2. Press and hold the RESET control for 2 seconds and release. Oil life is set to 100% and "OIL LIFE SET TO 100%" is displayed. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the instrument cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 100% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) NOTE:All message center functions are carried out using the single stem reset button in the instrument cluster (IC). NOTE:The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE:The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations View 151-5 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10920 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10921 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the engine oil pressure (EOP) switch electrical connector. ^ To install, tighten to 18 Nm (13 ft. lbs.) 3. Remove the EOP switch. ^ To install, tighten to 18 Nm (13 ft. lbs.) 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams C4015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams > Page 10925 Parking Assist Warning Indicator: Service and Repair PARKING AID SPEAKER Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 10929 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 10938 Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 10939 Vehicles with power tilt 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10944 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10945 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 10946 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10949 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10950 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 10951 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 10960 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10965 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 10971 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full TSB 08-19-1 09/29/08 LONG WHEEL BASE (LWB) - FUEL GAUGE READS BETWEEN 3/4 AND 7/8 WHEN FULL FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Question the customer - yes/no. a. Refueling event more than a 5 gallon fill? b. Customer refilled with the engine off? c. Customer refilled to 1 to 3 auto-shutoffs? NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full. 2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands. a. If not okay, refer to WSM recommendations. b. If okay, go to Step 3. 3. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester. a. If not, refer to WSM recommendations. b. If okay, go to Step 4. 4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod? a. If clearance is equal to or greater than specified, go to Step 6. b. If clearance is less than specified, go to Step 5. 5. Follow Pinpoint Test A Section 413-01: Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification? a. If within specification, follow WSM recommendation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-19-1 > Sep > 08 > Instruments - Fuel Gauge Reads Between 3/4 & 7/8 Full > Page 10976 b. If not within specification, go to Step 6. 6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. a. If blue pen mark is present, use the FDM as the replacement. b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT081901 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10977 Fuel Gauge Sender: Locations View 151-31 (Rear End - Expedition And Navigator) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10978 View 151-32 (Rear End - Expedition EL And Navigator L) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10979 C433 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10980 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10981 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the 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 (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10982 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Special Tool(s) Special Tool(s) 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. All fuel tanks Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 10983 1. Remove the fuel tank. 127L (33.5 gal) fuel tank 2. Remove the nuts and the fuel pump module cover. All fuel tanks 3. Disconnect the return fuel tube-to-fuel pump module quick connect coupling, the fuel tank pressure sensor and vapor tube assembly-to-fuel pump module quick connect coupling and the supply fuel tube-to-fuel pump module quick connect coupling. 4. Using the special tool, remove the fuel pump lock ring. 5. CAUTION: - 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. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-21 (LH A-Pillar - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 10987 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 10-4-2 > Mar > 10 > Instruments Speedo. Doesn't Return To Zero At A Stop Speedometer Head: Customer Interest Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 10-4-2 > Mar > 10 > Instruments Speedo. Doesn't Return To Zero At A Stop > Page 10996 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop Speedometer Head: All Technical Service Bulletins Instruments - Speedo. Doesn't Return To Zero At A Stop TSB 10-4-2 03/15/10 SPEEDOMETER - NOT RETURNING TO ZERO WHILE IN PARK AND ENGINE RUNNING FORD: 2007-2008 Expedition ISSUE Some 2007-2008 Expedition vehicles may exhibit symptoms of speedometer fluctuation while the engine is running and transmission is in park position. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 65.06 and higher. This new calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. 3. Verify that the 1CM Calibration shows 8L1P-7J104-AD (8L1P-7J104-BD for later production 2008 model year) part number after reprogramming is complete. a. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) 0DB Test Modes. (4) Mode Level 9 Vehicle Information. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR PROCEDURE TO BE FULLY EFFECTIVE 4. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and choose reset TCM KAM Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 10-4-2 > Mar > 10 > Instruments - Speedo. Doesn't Return To Zero At A Stop > Page 11002 NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE DISCONNECTING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 5. Verify the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 6. Drive unit to perform adaptive shift strategy learn. a. Accelerate from a stopped position with light throttle to 15 MPH (24 Km/h) and remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE SEVERAL DAYS OF DRIVING ARE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100402A 2007-2008 Expedition: 1.0 Hr. Reprogram The PCM And TCM Includes Time To Clear TCM KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS 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. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out the following procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire (as necessary). 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions: 1. 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 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB 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 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11010 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11013 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11014 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11015 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11016 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11017 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 11018 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Using a suitable tool, remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11030 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11031 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11032 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11037 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11038 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11039 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11040 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11041 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11042 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11043 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11044 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11045 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11046 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11047 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11048 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11049 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11050 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11051 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 Brake Lamp: Connector Views C4032 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11055 C4112 C4113 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11056 C4114 C4115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11057 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11058 90-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11059 90-3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11060 90-4 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 (2007)) 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. NOTE: Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is in the LOW BEAM position. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 9. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 10. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11063 B1485-B2047 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11064 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11065 Brake Lamp: Pinpoint Tests Test H: The Stoplamps Are Inoperative PINPOINT TEST H: THE STOPLAMPS ARE INOPERATIVE H1 H1-H2 Normal Operation The stoplamp switch is supplied voltage through circuit SBB31 (WH/RD) from the battery junction box (BJB). When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB) and the high mounted stoplamp through circuit CLS17 (YE/GY). Possible Causes - Fuse - Circuit CLS17 (YE/GY) open - Circuit SBB31 (WH/RD) open Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11066 - Stoplamp switch Test I: One Or More Stoplamps Are Inoperative PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE I1-I2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11067 I3-I7 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11068 I7-I9 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11069 I9-I10 Normal Operation When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB) and the high mounted stoplamp through circuit CLS17 (YE/GY). When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps, and the LH and RH trailer tow turn relays through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the LH and RH rear stoplamps is provided through circuits GD149 (BK/GY) and GD151 (BK/GN), respectively. Ground for the high mounted stoplamp is provided through circuit GD150 (BK/WH). DTC B2044 - is a continuous and on-demand DTC that sets when the SJB detects a short to ground on the LH rear stop/turn lamp voltage supply circuit. DTC B2045 - is an on-demand DTC that sets when the SJB detects an open on the LH rear stop/turn lamp voltage supply circuit. DTC B2046 - is a continuous and on-demand DTC that sets when the SJB detects a short to ground on the RH rear stop/turn lamp voltage supply circuit. DTC B2047 - is an on-demand DTC that sets when the SJB detects an open on the RH rear stop/turn lamp voltage supply circuit. Possible Causes - Circuit CLS17 (YE/GY) open - Circuit CLS18 (GY/BN) open or short to ground - Circuit CLS19 (VT/OG) open or short to ground - Circuit GD149 (BK/GY) open - Circuit GD150 (BK/WH) open - Circuit GD151 (BK/GN) open - High mounted stoplamp - Trailer tow turn relay - SJB Test J: The Stoplamps Are On Continuously PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11070 J1-J8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11071 J9-J10 When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB) and the high mounted stoplamp, the powertrain control module (PCM), the anti-lock brake system (ABS) module and the trailer electric brake controller through circuit CLS17 (YE/GY). When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps, and the LH and RH trailer tow turn relays through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. DTC B1485 - is an on-demand DTC that sets when the SJB detects a short to voltage from the stoplamp switch input circuit. DTC B2045 - is an on-demand DTC that sets when the SJB detects a short to voltage on the LH rear stop/turn lamp voltage supply circuit. DTC B2047 - is an on-demand DTC that sets when the SJB detects a short to voltage on the RH rear stop/turn lamp voltage supply circuit. Possible Causes - Circuit CCB08 (VT/WH) short to voltage - Circuit CLS17 (YE/GY) short to voltage - Circuit CLS18 (GY/BN) short to voltage - Circuit CLS19 (VT/OG) short to voltage - Stoplamp switch - Trailer electric brake controller - ABS module - PCM - SJB Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 11072 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11076 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11077 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11078 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation CAUTION: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams C926 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams C475 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams C2246 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams C254 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11105 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11106 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11107 Daytime Running Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11108 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11109 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11110 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11111 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11112 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11113 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11114 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11115 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11116 Daytime Running Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 97-1 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page 11117 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) NOTE: The smart junction box (SJB) must be configured when installing a new module. The DRL system operates the low beam headlamps at a reduced intensity. The SJB supplies pulse width modulated (PWM) voltage to illuminate the low beam headlamps at a reduced intensity when the following conditions are met: - The ignition switch is in the RUN position. - The headlamps have not been turned on by the autolamp system or the headlamp switch. - The transmission is not in PARK (P). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Inspection and Verification Daytime Running Lamp: Testing and Inspection Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the daytime running lamps (DRL) following these steps: - Place the ignition switch in the RUN position. - Place the headlamp switch in the OFF position. - Place the transmission in any gear other than PARK (P). - If the DRL does not operate, make sure the SJB is configured for DRL before proceeding to the next step. 2. Carry out the continuous and on-demand self tests for the SJB. - If any DTCs are retrieved related to the concern, refer to Body Control Systems (Multifunction Electronic Control Module). If no DTCs are retrieved, go to the next step. 3. For Expedition, verify the low beam operation. - Place the headlamp switch in the HEADLAMPS ON position. If the low beams do not operate correctly, refer to Lighting and Horns. - If the low beams operate correctly and the DRL operation is incorrect, proceed to the next step. 4. For Navigator, verify the fog lamp operation. - Place the ignition switch in the RUN position. - Place the headlamp switch in the HEADLAMPS ON position and engage the fog lamp switch. If the fog lamps do not operate correctly, refer to Lighting and Horns. - If the fog lamps operate correctly and the DRL operation is incorrect, proceed to the next step. 5. Check the SJB inputs. - Monitor the ignition switch, the headlamp switch input PIDs and the transmission gear status PIDs. If the ignition switch PIDs do not agree with the ignition switch position, refer to Ignition Switch. - If the transmission gear status PIDs do not agree with the gear selector lever position, refer to Transmission Control Systems. - If the headlamp switch PIDs do not agree with the headlamp switch position, refer to Lighting and Horns. - If the PIDs indicate correct ignition, headlamp switch and transmission gear status, install a new SJB. Refer to Body Control Systems (Multifunction Electronic Control Module). Test the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Inspection and Verification > Page 11120 Daytime Running Lamp: Testing and Inspection Principles of Operation PRINCIPLES OF OPERATION NOTE: When installing a new smart junction box (SJB), it must be configured for this feature, if originally equipped. Refer to Information Bus (Module Communications Network). The SJB controls the DRL by using various inputs to determine whether or not the DRL should be illuminated. These inputs include: - Ignition switch position - Headlamp switch position - Headlamps on or off - Transmission gear selection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 11121 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 11126 Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Instrument Panel Dimmer Switch > Page 11127 Vehicles with power tilt 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11132 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11133 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11134 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11137 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11138 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11139 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Removal and Installation WARNING: The fog lamp 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. - Make sure the headlamp switch and the ignition switch are in the OFF position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector and remove the fog lamp bulb. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Application and ID Hazard Warning Flasher: Application and ID The flasher function for this vehicle is provided by the Smart Junction Box (SJB). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 11151 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Expedition Headlamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11156 Navigator High Intensity Discharge (HID) Headlamp Bulb Removal and Installation WARNING: The headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: - The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamp with the bulb removed from the headlamp. - Make sure that the headlamp switch and the ignition switch are in the OFF position. All vehicles 1. Remove the headlamp assembly. Expedition 2. Rotate the headlamp bulb approximately 1/8 turn counterclockwise and remove the bulb from the headlamp assembly. Navigator 3. Remove the HID bulb access cover. 4. Remove the 2 screws and the HID bulb. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 11162 C2065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11165 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11166 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11167 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 11172 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11175 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11176 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11177 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11178 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11179 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11183 C205 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11184 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11185 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11186 Headlamp Switch: Service and Repair HEADLAMP SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11187 Navigator Removal and Installation Expedition 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations View 151-17 (Steering Wheel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 11192 C217 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11197 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11198 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11199 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11200 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11201 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11202 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11203 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11204 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11205 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11206 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11207 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11208 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11209 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11210 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11211 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11212 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11213 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11214 License Plate Lamp: Connector Views C452 C462 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11215 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 (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11216 92-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11217 92-3 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11222 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11223 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11224 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11225 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11226 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11227 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11228 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11229 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11230 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11231 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11233 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11234 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11235 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11236 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11237 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11238 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11239 Marker Lamp: Connector Views C151 C161 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11240 Marker Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11241 92-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11242 92-3 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 (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 11248 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11251 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11252 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11253 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11254 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11255 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11260 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11261 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11262 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 11267 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11270 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11271 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11272 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11273 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 11274 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 11279 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 11282 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11283 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11284 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11285 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11286 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11291 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11292 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11295 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11296 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11297 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11298 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11299 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11300 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11301 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11302 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Removal and Installation 1. Using a suitable tool, remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11310 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11311 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to 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: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11312 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation CAUTION: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair Console Lamp Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door latch. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11320 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11321 View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11322 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11325 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11326 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 11327 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11331 C2361 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 11337 C2065 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11340 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11341 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 11342 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11346 C205 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11347 Headlamp Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11348 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11349 Headlamp Switch: Service and Repair HEADLAMP SWITCH Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11350 Navigator Removal and Installation Expedition 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-17 (Steering Wheel - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 11354 C217 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11358 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11359 Turn Signal Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11360 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11361 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11362 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11367 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11368 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11369 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11370 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11371 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11372 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11373 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11374 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11375 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11376 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11377 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11378 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11379 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11380 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11381 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11382 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11383 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11384 Tail Lamp: Connector Views C4032 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11385 C4112 C4113 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11386 C4114 C4115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11387 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11388 92-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 92-3 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 (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 orientation. 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11403 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11404 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11405 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 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 (2007)) 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. 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 5 (40A) (trailer electric brake controller) - 12 (25A) (trailer tow parking lamps) - 13 (30A) (trailer tow battery charge relay switch side) - 34 (25A) (trailer tow turn relays) - 63 (15A) (trailer tow reversing lamps) - Smart junction box (SJB) fuse 42 (10A) (trailer tow battery charge relay coil) - Circuitry - Trailer tow turn/stop relays - Trailer tow battery charge relay - Trailer tow parking lamp relay - Trailer brake control module - Trailer - SJB 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11416 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11417 Trailer Lamps: Pinpoint Tests Test X: The Trailer Lamps Are Inoperative - All PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - ALL X1 X1 Continued Normal Operation The trailer tow connectors receive ground through circuit RAT08 (WH) for all of the trailer lamps. Possible Causes - Circuit RAT08 (WH) open - Trailer Test Y: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER TURN/STOPLAMP Y1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11418 Y1-Y2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11419 Y3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11420 Y4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11421 Y5 Normal Operation The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (OG). The battery junction box (BJB) fuse 34 (25A) supplies voltage to both trailer tow turn relays. The trailer tow turn/stop relay coils are grounded through circuit GD123 (BK/GY). Possible Causes - Fuse - Circuit CAT06 (YE) open - Circuit CAT09 (OG) open - Circuit CLS18 (GY/BN) open - Circuit CLS19 (VT/OG) open - Circuit GD123 (BK/GY) open - BJB - Trailer tow turn relay - Trailer Test Z: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11422 Z1-Z3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11423 Z3-Z4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11424 Z4 Continued Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11425 Z5 Normal Operation The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is grounded through circuit GD123 (BK/GY). The battery junction box (BJB) supplies voltage to the trailer tow parking lamp relay switch side through circuit SBB12 (GN/RD). When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). Possible Causes - Fuse - Circuit CAT11 (BN) open - Circuit CLS30 (VT/WH) open - Circuit GD123 (BK/GY) open - Circuit SBB12 (GN/RD) open - Trailer tow parking lamp relay - Trailer Tests AA: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS AA1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11426 AA1-AA2 Normal Operation The battery junction box (BJB) fuse 63 (15A) receives voltage from circuit CLS10 (GY/BN) when the vehicle reversing lamps are illuminated. The voltage is then routed to the trailer tow connector through circuit CAT16 (GY/BN). Possible Causes - Fuse - Circuit CAT16 (GY/BN) open - Circuit CLS10 (GY/BN) open - Trailer Tests AB: The Trailer Lamps Are On Continuously PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11427 AB1-AB2 Normal Operation - Trailer Tow Turn/Stoplamp The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed the trailer tow connector through circuit CAT06 YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (OG). Normal Operation - Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). Possible Causes - Circuit CAT06 (YE) short to voltage - Circuit CAT09 (OG) short to voltage - Circuit CAT11 (BN) short to voltage - Trailer tow relay - Trailer Tests AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11428 AC1-AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11429 AC3-AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11430 AC4-AC5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11431 AC5-AC6 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11432 AC6-AC8 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11433 AC8-AC10 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11434 AC10-AC11 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 42 (10A) through circuit CAT23 (GY/YE) when the ignition switch is in the RUN position. Ground for the trailer battery charge relay coil is supplied through circuit GD123 (BK/GY). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay switch side through circuit SSB13 (GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow connector through circuit CAT14 (OG). Possible Causes - Fuse - Circuit CAT14 (OG) open or short to voltage - Circuit CAT23 (GY/YE) open or short to voltage - Circuit GD123 (BK/GY) open - Circuit SSB13 (GY/RD) open - Trailer battery charge relay - Trailer - SJB Tests AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11435 AD1-AD2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11436 AD2-AD4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11437 AD5-AD7 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11438 AD8-AD9 Normal Operation The trailer brake control module is provided voltage at all times by the battery junction box (BJB) fuse 5 (40A) through circuit SBB05 (GY/RD). Ground for the trailer brake control module is provided through circuit GD138 (BK/WH). The trailer brake control module receives voltage from the stoplamp switch through circuit CLS17 (YE/GY) when the brake pedal is applied. When requested, the trailer brake control module sends voltage to the trailer tow connector through circuit CAT19 (BU). Circuit CLS30 (VT/WH) supplies voltage to the trailer brake control module when the parking lamps are on. Possible Causes - Fuse - Circuit CAT19 (BU) open, short to ground or voltage - Circuit CLS17 (YE/GY) open - Circuit CLS30 (VT/WH) open - Circuit GD138 (BK/WH) open - Circuit SBB05 (GY/RD) open - Trailer brake control module - Trailer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 11439 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11444 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11445 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11448 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11449 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11450 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left/Right Turn Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11451 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11452 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11453 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11454 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 11455 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application and ID Turn Signal Flasher: Application and ID The flasher function for this vehicle is provided by the Smart Junction Box (SJB). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11464 C4032 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11465 C1043 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11466 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11467 Turn Signal Lamp: Diagrams C1023 C4032 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11468 C1043 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11469 C156 C166 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11470 C4112 C4113 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11471 C4114 C4115 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11475 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11476 Turn Signal Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11477 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11478 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11479 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left C907 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 11484 C906 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11490 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11491 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11492 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11497 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11498 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11499 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 11504 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11507 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11508 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11509 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11510 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11511 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11517 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11518 View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11519 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11522 C535A C535B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11523 C701 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11524 C801 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11525 Power Window Switch: Diagrams Power Window Switch, RH Side Front C624 C648 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 11528 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11529 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11530 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11531 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 11532 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 11533 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. Unlock the tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR-FRONT DOOR Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 11539 Exploded View Removal and Installation NOTE: For Navigator, the LF/RF door power window regulator motor must be reinitialized whenever the LF/RF motor is removed from the vehicle. 1. Remove the front door trim panel. 2. Position the front door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator assembly to hold the window regulator assembly drum in place. Remove the bolts and the front door window regulator motor. 1 Disconnect the electrical connector. 2 Remove the bolts. To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - For Navigator, reinitialize the LF/RF window regulator motor. - Cycle the window glass to make sure the gears engage. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Service and Repair Quarter Window Motor: Service and Repair WINDOW REGULATOR MOTOR-REAR QUARTER Removal 1. Remove the D-pillar trim panel. 2. Disconnect the rear quarter window regulator motor. - Remove the retaining clip. 3. Remove the bolts and rear quarter window regulator motor. - To install, tighten to 9 Nm (80 lb-in). - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR-REAR DOOR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Page 11546 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel 2. Position the rear door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window regulator assembly to hold the window regulator assembly drum in place. Remove the rear door window regulator motor. 1 Disconnect the electrical connector. 2 Remove the bolts. To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 11551 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11554 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11555 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11556 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11557 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 11558 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-35 (Driver Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11563 View 151-36 (Passenger Door - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11564 View 151-39 (LH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11565 View 151-40 (RH Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11568 C535A C535B Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11569 C701 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11570 C801 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11571 Power Window Switch: Diagrams Power Window Switch, RH Side Front C624 C648 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11574 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11575 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11576 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11577 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11578 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 11579 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. Unlock the tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-FRONT Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 11585 Exploded View 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair WINDOW GLASS-LIFTGATE Material Material Removal and Installation Window glass assembly 1. Remove the rear window wiper motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11589 2. Disconnect the rear window defrost electrical connectors. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11590 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair WINDOW GLASS-REAR QUARTER Material Material Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 11594 Part 2 Removal All vehicles 1. Remove the rear quarter trim panel. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 11595 5. Disconnect the audio antenna. 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 core butyl from the window opening. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 11596 1. Apply 8 mm (0.32 in) Foam Core Butyl or equivalent meeting Ford specification WSB-M3G143-B1 to the rear quarter window glass frame. - Start at the bottom middle and work around the frame. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Install the rear quarter window glass nuts. Tighten to 2 Nm (18 lb-in). 3. If equipped, install the air duct. - Install the pin-type retainer. 4. Connect the audios antenna. Vehicles with power vent windows Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 11597 5. Install the rear quarter window regulator. 6. Install the bolts and rear quarter window regulator motor. - Tighten to 9 Nm (80 lb-in). - Connect the electrical connector. 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN-REAR Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 11602 Part 2 Exploded View 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 (2007)) 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 Part 1 Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11607 Exploded View Removal and Installation NOTE: For Navigator, the LF/RF door power window regulator motor must be reinitialized whenever the LF/RF window regulator is removed from the vehicle. 1. Remove the front door trim panel. 2. Unlock the tabs and remove the window control switch from the door trim panel. 3. Remove the screws and the front door speaker. - Disconnect the electrical connector. 4. Remove the front door weathershield. 5. Re-connect the electrical connectors to the window control switch. 6. Lower the window glass to access the 2 window glass clamp bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11608 7. Loosen the window glass clamp bolts. - To install, raise the window glass until it stalls in the UP position. Tighten the window glass clamp bolts to 11 Nm (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. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11609 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. 14. For Navigator, reinitialize the LF/RF window regulator motor. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11613 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel 2. NOTE: LF shown, LR and RR are similar. Unlock the tabs and remove the window control switch from the door trim panel. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11614 4. Remove the rear door weathershield. 5. Connect the window control switch. 6. Lower the window glass to access the window glass clamp bolts. 7. Disconnect the window control switch. 8. Loosen the window glass clamp bolts and remove the rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 9. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the front door frame. 10. Disconnect the rear door window regulator electrical connectors. 11. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11615 12. Remove the rear door window regulator assembly. - Remove the bolts. To install, tighten to 11 Nm (8 lb-ft). 13. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 (2007)) 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 11624 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 (2007)) 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 11625 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 (2007)) 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 11626 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 (2007)) 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 11627 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 (2007)) 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 (2007)) 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 11633 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 (2007)) 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 11634 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 (2007)) 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 11635 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 (2007)) 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 11636 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front/Rear Suspension Squeak/Rattle TSB 08-19-11 09/29/08 SQUEAK / RATTLE FRONT OR REAR SUSPENSION FORD: 2007-2008 Expedition LINCOLN: 2007-2008 Navigator ISSUE Some 2007-2008 Expedition and Navigator vehicles may exhibit a squeak noise from the front or rear suspension. The source of the noise may be the lower shock attachment bolt and nut. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use chassis ears to confirm the noise is coming from the shock to lower control arm attachment nut and bolt. 2. If confirmed, loosen the nut and bolt and re-torque to the 350 lb-ft (475 N.m) specification in the Workshop Manual (WSM), Section 204. 3. Retest for the noise. If concern still exists, replace the shock, nut and attaching bolt per WSM, Section 204. 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 081911A 2007-2008 Expedition, 1.3 Hrs. Navigator: Diagnosis, Includes Time To Install Chassis Ears, and Torque Fasteners. Includes All Necessary Road Tests, This Labor Operation Can Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle > Page 11642 Be Claimed With Any Of the Operations In This Article (Do Not Use With 18124A, 18125A, 5649A) 081911B 2007-2008 Expedition, 0.7 Hr. Navigator: Replace One Front Shock This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911C 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace Both Front Shocks This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911D 2007-2008 Expedition, 0.9 Hr. Navigator: Replace One Rear Shock This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A 18125A, 5649A) 081911E 2007-2008 Expedition, 1.7 Hrs. Navigator: Replace Both Rear Shocks This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A, 18125A, 5649A) DEALER CODING CONDITION BASIC PART NO. CODE 18125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-19-11 > Sep > 08 > Suspension - Front/Rear Suspension Squeak/Rattle > Page 11648 Be Claimed With Any Of the Operations In This Article (Do Not Use With 18124A, 18125A, 5649A) 081911B 2007-2008 Expedition, 0.7 Hr. Navigator: Replace One Front Shock This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911C 2007-2008 Expedition, 1.1 Hrs. Navigator: Replace Both Front Shocks This Labor Operation Can Be Claimed With Operations A, D Or E (Do Not Use With 18124A 18125A, 5649A) 081911D 2007-2008 Expedition, 0.9 Hr. Navigator: Replace One Rear Shock This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A 18125A, 5649A) 081911E 2007-2008 Expedition, 1.7 Hrs. Navigator: Replace Both Rear Shocks This Labor Operation Can Be Claimed With Operations A, B Or C (Do Not Use With 18124A, 18125A, 5649A) DEALER CODING CONDITION BASIC PART NO. CODE 18125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures Windshield: Procedures WINDSHIELD RESEAL Material Material 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 8 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 glass cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11653 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. 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 8 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 glass cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11654 Windshield: Removal and Replacement WINDSHIELD GLASS Special Tool(s) Special Tool(s) Material Material Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11655 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11656 5. Remove the sun visors. 1 Remove the 8 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11657 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11658 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 glass 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11659 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 (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 11660 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 8 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 (2007)) 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 - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11666 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11670 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11673 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11674 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11675 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11676 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11677 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11678 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11682 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11685 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11686 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11687 Wiper Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11688 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11689 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11690 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11694 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations View 151-2 (Engine Compartment - Expedition (Page 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 11698 C1357 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair WASHER PUMP Removal and Installation WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the container. Failure to follow these instructions could result in personal injury. CAUTION: - When servicing the windshield washer pump be careful not to damage the windshield washer pump seal. - Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. 1. Remove the RH headlamp assembly. 2. Position aside the shield as necessary to gain access to the washer pump. 3. Disconnect the windshield washer reservoir hoses. 4. Disconnect the windshield washer pump electrical connector. 5. Remove the windshield washer pump. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER RESERVOIR Removal and Installation WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the container. Failure to follow these instructions could result in personal injury. CAUTION: - When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. - Do not operate the windshield pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. NOTE: The washer reservoir is integrated with the battery tray and cannot be serviced separately. 1. Remove the vehicle battery. 2. Drain the cooling system. 3. Disconnect the upper radiator hose at the radiator inlet, and position aside. 4. Remove the 3 battery tray bolts. - To install, tighten to 17 Nm (13 lb-ft). 5. Carefully position the washer reservoir assembly to gain access to the electrical connectors and washer hoses. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 11705 6. Disconnect the windshield washer solvent level electrical connector, washer pump electrical connectors and washer hoses. 7. NOTE: If necessary, drain the windshield washer reservoir after removal. Remove the washer reservoir assembly. 8. Transfer components as necessary. 9. To install, reverse the removal procedure. - Refer to Cooling System for coolant filling and bleeding procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11709 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11712 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11713 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11714 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11715 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11716 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11717 2. Remove the 3 screws and the upper and lower steering column shrouds. ^ Disconnect the power tilt electrical connector switch from the lower shroud. Vehicles with manual tilt 3. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 4. Remove the 3 screws and the upper and lower steering column shrouds. All vehicles 5. Disconnect the multi-function switch electrical connector. 6. Remove the 2 screws and the multi-function switch. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Windshield WIPER BLADE AND PIVOT ARM ADJUSTMENT - WINDSHIELD 1. Cycle and park the windshield wipers. 2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) 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 35 Nm (26 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield > Page 11722 Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Rear WIPER BLADE AND PIVOT ARM ADJUSTMENT - REAR 1. Cycle and park the rear window wiper pivot arm and blade. 2. Check the rear window wiper park measurement. If not within specification, 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 35 Nm (26 lb-ft). 3 Install the cover. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front Wiper Arm: Service and Repair Wiper Pivot Arm - Front WIPER PIVOT ARM - FRONT Removal and Installation 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 35 Nm (26 lb-ft). 5. To install, reverse the removal procedure. - Adjust the windshield wiper pivot arms. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 11725 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 11726 Wiper Arm: 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 11727 Wiper Arm: Service and Repair Wiper Mounting Arm and Pivot Shaft - Rear WIPER MOUNTING ARM AND PIVOT SHAFT - REAR Removal and Installation 1. Remove the rear wiper pivot arm. 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor View 151-1 (Engine Compartment - Expedition (Page 1 Of 2)) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor > Page 11732 View 151-41 (Liftgate - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) 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 Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11735 Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in Symbols. Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11736 orientation. 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11737 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11738 Location information that can be found at the vehicle level will helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11739 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11740 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11741 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11742 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11743 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. Defective insulation stripping 1 = Proper crimp Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11744 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11745 Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11746 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11747 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11748 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11749 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11750 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11751 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11752 Wiper Motor: Connector Views C476 C125 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield Wiper Motor: Service and Repair Wiper Motor - Windshield WIPER MOTOR - WINDSHIELD Removal and Installation 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 lb-ft). 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. See: Testing and Inspection/Component Tests and General Diagnostics/Windshield Wiper Motor To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 11755 Wiper Motor: Service and Repair Wiper Motor - Rear Window WIPER MOTOR - REAR WINDOW 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 11756 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. 1 Tighten bolts to 8 Nm (71 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 11757 2. NOTE: An audible click should be heard as the striker engages the latch. Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is provided with the motor assembly. 1 Make sure the alignment tool fits over the motor disc and striker assembly. 2 Make sure the alignment tool clips are securely engaged. 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 11758 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 (2007)) 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 (2007)) 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 11767 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 (2007)) 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 11768 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 (2007)) 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 (2007)) 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 11774 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 (2007)) 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 11775 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 11776 Wiper Pivot: Service and Repair STRIKER AND WIPER PIVOT SHAFT ASSEMBLY - REAR 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 11777 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 11778 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 (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-15 (Steering Column - Expedition) Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11782 C202 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11785 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11786 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11787 Wiper Switch: Testing and Inspection Multifunction Switch Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 11788 Ford Expedition 4wd Workshop Manual (V8-5.4L (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11789 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation All vehicles 1. Remove the 3 screws, pull out to release the top retaining clips and remove the lower steering column opening cover. Vehicles with power tilt