Ford - Explorer Sport Trac 4wd - Workshop Manual - 2008 - 2008

Factory Workshop Manual Make Ford Model Explorer Sport Trac 4wd Engine and year V8-4.6L (2008) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 21 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 22 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 27 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 28 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 38 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 39 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 44 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 45 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Audio Control Module View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Audio Control Module > Page 48 View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) C3342 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 51 C3342 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 52 Communications Control Module: Diagrams Audio Control Module C290A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 53 C290B C290C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Page 54 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - When installing a new navigation audio control module (ACM), remove the navigation DVD before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. NOTE: Module configuration is only required if a new ACM is being installed. Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module Configuration) to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors and the antenna lead-in cable(s). 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 63 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 64 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 69 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 70 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 71 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 72 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 73 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 74 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 75 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 76 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 77 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 78 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 79 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 85 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 86 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 91 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 92 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 93 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 94 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 95 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 96 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 97 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 98 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 99 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 100 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 101 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 106 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 107 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 113 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 114 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 136 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 137 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 143 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 144 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 153 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 154 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 160 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 161 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 165 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 166 View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 167 Parking Assist Control Module: Diagrams C3267 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 168 C4014 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 169 C4226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 170 Parking Assist Control Module: Service and Repair Parking Aid Module Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 171 Explorer Sport Trac Removal and Installation Mountaineer 1. Remove the RH quarter trim panel. Explorer Sport Trac 2. Remove the cab rear trim panel. Mountaineer 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Remove the parking aid speaker push pins. - Remove the parking aid speaker. Explorer Sport Trac 4. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. All vehicles 5. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 172 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 177 Memory Positioning Module: Diagrams C341A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 178 C341B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 179 C341C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 180 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 181 Part 2 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. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed (if it was replaced) it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 186 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 187 Power Seat Relay: Locations Third Row Folding Seat Relay, Right View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 188 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 191 C4184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 194 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 195 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 196 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 200 Auxiliary Step / Running Board Module: Diagrams C4322A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 201 C4322B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 202 Auxiliary Step / Running Board Module: Service and Repair POWER RUNNING BOARD (PRB) MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 206 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 207 C921 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 211 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 216 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 217 Electronic Brake Control Module: Diagrams C155 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 218 C155 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 219 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Programmable Module Installation in Information Bus (Module Configuration). 1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 lb-in). 3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the hydraulic control unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 223 C239 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 229 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 230 View 151-38 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay C3023 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 233 C2017 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 236 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 237 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 238 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 242 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 243 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 247 Control Module HVAC: Diagrams C228A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 248 C228B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 258 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 264 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 273 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 279 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 284 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 291 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 302 Part 2 Removal CAUTION: - If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 303 9. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 10. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11 If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower, right SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: - When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. - When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry Transmitter Programming Download the SJB configuration information from the scan tool into the new SJB. 15. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 304 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear the DTC C2780. Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 312 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 313 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 314 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 315 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 316 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 317 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 318 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 319 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 320 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 321 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 322 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 325 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 326 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 327 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 328 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 329 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 330 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 333 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 334 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 335 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 336 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 337 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 338 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 339 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 340 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 341 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 342 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 343 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (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 The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 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. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 349 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 350 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 351 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 separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 355 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 356 View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 357 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 362 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 366 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 369 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 370 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 371 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 372 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 374 C175B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 375 C175E (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 376 C175E (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 377 C175E (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 378 C175T (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 379 C175T (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 382 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) A/C Tube Brackets Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 383 PCM Removal All vehicles 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 384 - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 388 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 393 C1450 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations Fuel Pump Control Unit: Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 398 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 399 C4033 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 400 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 404 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 408 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 413 View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 414 View 151-21 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit C216C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 417 Air Bag Control Module: Diagrams Restraints Control Module C310A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 418 C310B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 419 C310B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 420 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 421 - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: When installing a new RCM, it is necessary to carry out programmable module installation (PMI). System failure may occur if PMI is not performed. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 422 5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle may cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. - CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 423 7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9. Carry out the steps necessary to complete PMI. 10. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 427 C3159 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 428 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM) Removal and Installation NOTE: - The air bag warning indicator 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 shown, manual seat similar. - Seat is removed for clarity. 1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant classification system module (OCSM) electrical connector. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 429 out the SRS. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 435 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 438 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 439 Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 440 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 446 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 451 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 454 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 455 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 456 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 462 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 463 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 466 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 467 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 468 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 469 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 470 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 475 C4323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 479 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 485 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 488 C4011 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 489 C4010 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 490 C4012 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 491 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s). 3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 495 C2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 499 C2208 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 504 C2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 509 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 512 C605 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 513 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 514 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 515 - Release the 4 retaining tabs. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 519 C527 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 520 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 521 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 522 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch Power Seat Switch: Locations Third Row Folding Seat Switch View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 527 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 528 View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 529 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 530 Power Seat Switch: Locations Power Seat Switch View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 531 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch Power Seat Switch: Diagrams Power Seat Switch C352 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 534 C3016 C355 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 535 Power Seat Switch: Diagrams Third Row Folding Seat Switch C4179 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 536 C4180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 539 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 540 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 541 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 542 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 546 C4039 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 550 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 553 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 554 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 555 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 556 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 557 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 558 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation NOTE: - The air bag warning indicator 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 front seat. 2. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. 7 Separate the cushion trim cover elastic strap from the cushion side shield. 8 Remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 559 Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 563 C2094 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 567 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 568 Sunroof / Moonroof Switch: Diagrams C912 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 569 C9001 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 570 C9038 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 573 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window Motor Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 574 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium Overhead Console Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 575 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 579 C479 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 584 C3073 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 585 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 586 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 590 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 591 C149 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 595 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 596 C124 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 600 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 604 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 605 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 612 C280 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 613 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 lb-in). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 614 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 619 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 620 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 621 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 622 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 623 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 624 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 625 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 628 C160 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 629 C440 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 630 C426 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 633 ^ To install, tighten to 17 Nm (13 lb-ft). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 634 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear 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 wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Page 638 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 650 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 651 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 652 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch Brake Switch (Cruise Control): Locations Deactivator Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 658 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 659 Brake Switch (Cruise Control): Locations Brake Pedal Position Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 660 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 663 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 664 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 665 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 673 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 674 C103 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 682 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 683 C132 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 684 Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 685 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-39 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 689 C271 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 690 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 switch resistor in all function selector switch positions except OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 691 Switch - Blower Motor, Front Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 692 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 696 C233 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 697 Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 698 Cabin Temperature Sensor / Switch: Service and Repair 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 705 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch C130 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 708 C1078 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C compressor clutch when the suction pressure in the low-pressure side of the refrigerant system drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage the A/C compressor clutch. The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator. It is not necessary to recover the refrigerant before removing the A/C cycling switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 711 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 Air Conditioning System Overview. 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. 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. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 712 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 716 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Release the 2 tabs and remove the instrument panel dimmer switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 721 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 726 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 727 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 728 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 729 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 732 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 733 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 734 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 735 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 738 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 739 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 740 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 741 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 742 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 743 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 744 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams C434A C434B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 748 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 749 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 750 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 751 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 752 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 756 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 757 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 762 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 763 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 767 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 768 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 772 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 773 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 774 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 775 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 780 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 781 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 782 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 783 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 786 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 787 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 788 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 789 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 792 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 793 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 794 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 795 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 796 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 797 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 798 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 803 Headlamp Dimmer Switch: Locations Multifunction Switch View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 804 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 807 C2298 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 810 Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 811 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 812 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 813 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 817 C205 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 818 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 819 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 820 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 827 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 828 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 829 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 830 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 831 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 837 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 838 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 842 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 843 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 844 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 845 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 846 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 851 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 852 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 855 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 856 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 857 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 858 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 868 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 869 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 870 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 871 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 872 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 873 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 877 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 878 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 879 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 883 Fuel Level Sensor: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 884 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 885 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 889 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 890 C435 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 891 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 892 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel tank. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 893 3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 897 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 898 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 899 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 900 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 901 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 905 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 906 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 913 C104 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 914 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 915 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 920 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 921 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 922 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 923 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 924 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 925 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 926 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 927 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 930 C142 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 931 C171 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 932 C172 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 933 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. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 936 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 937 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 938 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 939 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 940 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 944 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 945 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 949 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 953 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 954 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 955 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 956 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 957 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 958 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 962 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 965 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 966 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 967 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 968 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 969 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 970 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 971 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 972 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 973 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 974 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 975 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 976 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 977 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 978 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 979 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 980 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 981 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 982 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 983 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 984 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 985 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 986 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 987 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Vehicle Speed Sensor: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 995 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1000 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1001 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1005 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1006 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1007 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1008 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1009 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1013 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1014 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1015 Fuel Pressure Sensor/Switch: 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1016 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1020 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1021 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1022 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1023 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1027 C282 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1028 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, Roadside Emergencies for the location of the IFS switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1029 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1033 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1034 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1035 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1036 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1037 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1038 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 1044 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 1045 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 1048 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 1049 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1050 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1051 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1059 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1060 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor Impact Sensor: Locations Forward Crash Sensor View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1066 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1067 View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1068 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1069 Impact Sensor: Locations Side Impact Sensor View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1070 View 151-23 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1071 View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1072 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1073 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 1074 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor Impact Sensor: Diagrams Forward Crash Sensor C1465 C1466 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 1077 Impact Sensor: Diagrams Side Impact Sensor C567A C644A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 1078 C3248 C3249 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1081 - 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. Depower the SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1082 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint (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. - RH shown, LH similar. - The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1083 5. Position aside the lower C-pillar trim panel. - Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the C-pillar side impact sensor. 6. NOTE: - Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts from the side impact sensor and bracket assembly. - To install, tighten to 12 Nm (9 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1084 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. - Driver side shown, passenger side similar. 1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. NOTE: - Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1085 Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 1090 View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 1093 C3066 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left > Page 1098 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left C3291 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left > Page 1101 C3292 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1102 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification sensor (OCS) system is standard equipment on all front passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1103 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1104 Part 2 Removal WARNING: - The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. - Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: - The air bag warning indicator 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 perform the diagnostic procedure again. - Outboard shown, inboard similar. 1. Remove the passenger seat. 2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then, using a suitable tool, release the tab and disconnect the OCS rail electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1105 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1106 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: - If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. - To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1107 - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat. Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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 shown, manual seat similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Note the position of the seat position sensor locating tab for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Page 1111 Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1115 C356 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1124 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1125 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1131 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1132 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1136 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1137 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1142 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1143 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1149 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1150 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1153 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1154 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1155 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1156 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1157 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1158 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1165 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1166 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1167 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1168 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1169 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1170 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1171 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1172 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1173 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1174 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1175 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1176 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1177 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 1178 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1183 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1184 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1185 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1186 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1187 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1188 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1189 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1190 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1191 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1192 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1193 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1194 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1195 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1200 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1201 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1202 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1203 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1204 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1205 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1206 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1207 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1208 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1209 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1210 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1211 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1212 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1218 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1219 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1220 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1221 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1222 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1223 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1224 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1225 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1226 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1227 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1228 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1229 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1230 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 1233 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 1234 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1238 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1241 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1242 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1243 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1244 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1245 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1246 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1247 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1248 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1249 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1250 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1251 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1252 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1253 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1254 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1255 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1256 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1257 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1258 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1259 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1260 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1261 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1262 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1263 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1268 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1269 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1270 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1273 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1274 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1275 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1276 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1277 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1278 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1279 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1280 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1281 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1282 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1283 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1284 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1285 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1286 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1287 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1290 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1291 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1292 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1293 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1294 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1295 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1296 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1297 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1298 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1299 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1300 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1301 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1302 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1303 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1304 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1305 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 1306 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1311 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1312 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1313 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1314 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1315 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1316 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1317 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1318 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1319 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1320 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1321 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1322 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1323 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1328 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1329 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1330 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1335 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 1340 Power Window Switch: Locations Window Adjust Switch View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 1341 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 1342 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 1343 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch C980 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1346 Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1347 C504B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1348 Power Window Switch: Diagrams Window Adjust Switch C604 C701 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1349 C801 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1352 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1353 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1354 Power Window Switch: Testing and Inspection Rear Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1355 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1360 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1361 C138 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1365 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1366 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1369 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1370 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1371 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1372 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1376 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1377 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1380 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1381 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1382 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1383 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1389 Alignment: Specifications General Specifications General Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1390 Alignment: Specifications Torque Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1391 Alignment: Description and Operation Suspension System The front camber and caster are adjusted by loosening the upper control arm bolts which will allow the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole. Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by replacing the upper arm inboard flagnut with a non-flagnut to allow the arm to be adjusted in the slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1392 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow. Wander 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 and 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 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1. Using alignment equipment and the manufacturer's instructions, measure the front caster and camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the following chart. ^ When making adjustments that require moving both the front and the rear of the upper arm, move both ends of the arm equally. 3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber settings are not disturbed while tightening the bolt(s). Tighten the upper arm bolt(s) to 150 Nm (111 lb-ft). 4. NOTE: caster split adjustment can be made by loosening the LF lower arm rearward nut and adjusting the rear of the LF lower arm. Remove and discard the LF lower control arm rearward nut. 5. NOTE: Do not fully tighten the nut and bolt at this time. Install a new LF lower arm rearward nut. 6. Position the LF lower arm until the caster split is within specification. 7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are not disturbed while tightening the nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1395 Tighten the LF lower arm rearward nut to 200 Nm (148 lb-ft). 8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1396 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the lower arm inboard bolt. ^ Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement A). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1397 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm until the scriber point is located in the center of the shock absorber lower bolt. ^ Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement B). 5. Subtract measurement B from measurement A to obtain the front ride height. ^ Refer to Specifications. Rear Ride Height Measurement Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1398 Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt (measurement A). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement B). 3. Subtract measurement B from measurement A to obtain the rear ride height. ^ Refer to Specifications. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1399 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is rotated. Remove the clamps. 5. Loosen the tie-rod jam nuts. 6. Rotate the front wheel inner tie rods until the toe setting is within specification. 7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the steering gear bellows can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the nuts. Tighten the tie-rod jam nuts to 70 Nm (52 lb-ft). 8. Install the clamps. 9. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1400 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard nut. 5. Rotate the rear toe link cam bolt until the toe setting is within specification. 6. NOTE: Make sure the toe settings are not disturbed while tightening the nut. While holding the adjustment cam bolt, tighten the toe link inboard nut. ^ Tighten to 275 Nm (202 lb-ft). 7. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1401 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear 1. Index-mark the upper arm inboard bolt to the frame. 2. NOTE: The upper arm inboard flagnut must be removed and replaced with a non-flagnut to allow for the adjustment of the arm in the frame slot. Remove and discard the upper arm inboard bolt and flagnut. ^ Install a new non-flagnut. 3. Using alignment equipment and the manufacturer's instructions, measure the rear camber. 4. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber. NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber. NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the upper arm outward. Position the upper arm until the camber setting is within specification. 5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1402 Tighten the upper arm inboard nut to 250 Nm (185 lb-ft). 6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 (KOEO).............................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1407 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 4.6L shown, 4.0L similar. Install the special tool in line between the fuel supply tube and fuel rail. 3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1408 6. NOTE: - 4.6L shown, 4.0L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 630 - 850 RPM ................................................................................................ ...................................................................................................... Hot Idle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1416 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1417 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing..............................................................................................................................................10 degrees before top dead center (BTDC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 1431 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1436 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1437 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1438 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1439 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1440 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1441 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1442 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1443 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1444 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1445 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1446 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap (not adjustable)............................................................................................................ ...................................1.02-1.28 mm (0.040-0.050 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 1449 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1450 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type (early build - black coil boot)....................................................................................... ....................................................................PZT-14F Spark plug type (late build - brown coil boot).... ....................................................................................................................................................HJFS -24FP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1451 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. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1452 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(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1453 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1454 Spark Plug: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1455 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1459 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 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1460 Compression Pressure Limit Chart (Part 2) If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1472 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1478 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1479 Drive Belt: Diagrams Component Locations - 4.6L (3V) Component Locations - 4.6L (3V) (Part 1) Component Locations - 4.6L (3V) (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart Belt Tensioner With Belt Length Indicator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1482 3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service limit. Install a new belt as necessary. 4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 5. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1483 6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be considered acceptable. If cracks exceed this standard, install a new belt. V-Ribbed Serpentine Belt With Piling 7. 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. V-Ribbed Serpentine Belt With Chunks of Rib Missing 8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1484 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1485 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1486 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt - Noise/Flutter CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1487 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. 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 from the tensioner. Carry out the following tests: ^ Using the release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. ^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. ^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1488 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1489 Drive Belt: Service and Repair Accessory Drive Belt - 4.6L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V) Removal and Installation 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1490 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1496 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1497 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not factory equipped with a Cabin Air Filter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor hose from the dust separator. 5. Remove the bolt and the dust separator. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 7. Leak test the evaporative emission (EVAP) system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection 8. Carry out the evaporative emission repair drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission Fluid Filter - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid drain plug and drain the transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1508 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. 5. Remove and discard the transmission fluid pan filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1509 Installation 1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1510 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. Install the transmission fluid drain plug. ^ Tighten to 26 Nm (19 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1511 7. Partially fill the transmission. Transmission Filter - In Line Transmission Filter - In Line NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or in-line transmission fluid filter kit. ^ If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1512 3. Using the special tool, disconnect the transmission fluid cooler connector. 4. Remove the section of the transmission fluid cooler tube at the second flare. ^ Clean and deburr the cut end of the transmission fluid cooler tube. 5. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 6. Remove the section of the transmission fluid cooler hose as illustrated. 7. CAUTION: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the transmission fluid filter indicates the direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in the transmission fluid cooler return line with the red arrow on the transmission fluid filter pointing away from the transmission fluid cooler and toward the transmission (the transmission fluid return line has transmission fluid coming out of the transmission fluid cooler going to the transmission). If the transmission fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a bend entering the transmission fluid filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal transmission damage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1513 Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a clamp. ^ Tighten the transmission fluid cooler hose clamp. 8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing ferrule hose assembly with 2 clamps. ^ Tighten the hose clamps. 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1514 Fluid Filter - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1515 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 transmission fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter seal is in the case, carefully remove the transmission fluid filter seal without scratching the case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1516 2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the transmission fluid filter seal with clean transmission fluid. 3. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 1517 Install a new transmission fluid pan gasket if required. 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1527 Removal and Installation 1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 4. Disconnect the electrical connector. 5. Loosen the generator nuts. ^ To install, tighten to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1528 6. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket and wiring harness aside as an assembly. ^ To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. ^ To install, tighten to 10 Nm (89 lb-in). 11. To install, reverse the removal procedure. ^ Install new gaskets. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 1533 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 1534 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the compressor outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1539 - To install, tighten to 8 Nm (71 lb-in). 9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected from the cooling module. Detach the 2 compressor-to-condenser discharge line clips at the cooling module. 10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1540 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the PCM and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1541 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 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. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1542 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1543 Part 2 Removal and Installation 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1544 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1545 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1546 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the compressor outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet fitting nut and disconnect the fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1547 - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected from the cooling module. Detach the 2 compressor-to-condenser discharge line clips at the cooling module. 10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the PCM and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1548 Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 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. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1549 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1550 Part 2 Removal and Installation 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1551 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1552 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Suction Accumulator To Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1553 Removal and Installation 1. Recover the refrigerant. 2. Remove the suction accumulator outlet fitting nut. - To install, tighten to 8 Nm (71 lb-in). 3. Disconnect the auxiliary evaporator outlet line fitting. - Discard the O-ring seals. 4. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the rear suction accumulator-to-compressor line. - Discard the O-ring seal. 7. NOTE: The compressor suction fitting nut can be accessed through the RH wheel well. Remove the compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1554 8. Remove the front suction accumulator-to-compressor line. 9. To install, reverse the removal procedure. - Install new O-ring seals and a new gasket seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Suction Accumulator To Evaporator Line SUCTION ACCUMULATOR TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the suction accumulator. 2. Remove the A/C line bracket nut at the dash panel and remove the A/C line bracket. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the ground strap bolt at the dash panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1555 4. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Vehicles with 4.0L engine 5. Disconnect he evaporative emissions return line fitting at the intake manifold. 6. Remove the fuel line bracket bolt at the rear of the RH valve cover. 7. Remove the wire harness bolt at the rear of the RH cylinder head. All vehicles 8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1556 - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1560 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the power steering fluid cooler from the steering gear. ^ Discard the O-ring seal. 5. Disconnect the pressure line from the steering gear. ^ Discard the O-ring seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1561 6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). 7. Remove the pressure line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting. ^ Remove and discard the Teflon(R) seal. 9. Remove the pressure line. Installation 1. NOTE: new Teflon(R) seal must be installed. Using the special tool, install a new Teflon(R) seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 lb-ft). 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). ^ Tighten to 11 Nm (8 lb-ft). 4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are disconnected from the steering gear. Install a new O-ring seal and position the pressure line to the steering gear. 5. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 12 Nm (9 lb-ft). 6. Install a new O-ring seal and position the power steering fluid cooler to the steering gear. Rotate the steering line clamp plate into position. 7. Install the steering line clamp plate nut. ^ Tighten to 25 Nm (18 lb-ft). 8. Install the power steering pump pulley. 9. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Part Number ................................................................................................................................ ................................................... PM-1 or PM-1-C Ford Specification ...................................................................................................................................................... ESA-M6C25-A or WSS-M6C62-A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. .............................................. 13.9 quarts (13.2 liters) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1570 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford Part Number ................................................................................................................................ .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Note: Add the coolant type originally equipped in your vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 5R55S .................................................................................................................. ............................................................................. 12.4 quarts (11.7 liters) 6R60 ................................ .............................................................................................................................................................. .... 11.2 quarts (10.6 liters) Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be checked by a qualified technician. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1575 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type 5R55S .................................................................................................................................................. ............................................. MERCON V XT-5-QM 6R60 .................................................................. ............................................................................................................................. MERCON SP XT-6-QSP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission Fluid - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission Transmission Fluid Level Check Transmission Fluid Level Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1578 Transmission Fluid Fill Reference 1. Using the scan tool, monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27-49° C (80-120° F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. 7. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1579 8. Install the special tool into the pan. 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1580 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission fluid pan. 13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the transmission fluid level in the special tool. If the transmission fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra transmission fluid trapped in the system and direct it into the container. 16. Allow the transmission fluid to drain. Make sure that the fluid temperature is between 27-49° C (80-120° F). When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1581 17. Reinstall the small (center) transmission fluid level indicating plug using a 3/16-inch Allen key. ^ Tighten to 10 Nm (89 lb-inch). 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Transmission Fluid Drain and Refill - Automated Equipment Transmission Fluid Drain and Refill - Automated Equipment Draining CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. CAUTION: Always refer to the instructions supplied with the flush and fill machine or transmission damage can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1582 1. With the vehicle in PARK, position it on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission fluid cooler tube after the transmission fluid cooler on the transmission fluid cooler return tube. This will help remove any foreign material trapped in the transmission fluid coolers. Refill 1. Use only clean transmission fluid. 2. Once the transmission fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the engine running, check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. For additional information, refer to Transmission Fluid Level Check. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Transmission Fluid Level Check Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1583 Fluid Fill Reference NOTE: Left side of case shown. Fluid Fill Reference Draining 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2. Remove the transmission fluid drain plug (large plug) and allow the fluid to drain. Refill 1. Install the transmission fluid drain plug. ^ Tighten to 26 Nm (19 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1584 2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 3. Install the special tool into the transmission fluid pan. 4. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1585 5. Hang the special tool under the vehicle, upright and close to the transmission. 6. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1586 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the transmission fluid temperature is between 27° C-49° C (80° F-120° F). 10. Inspect the transmission fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the transmission fluid to drain. When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. 13. Reinstall the small (center) transmission fluid level indicating plug. ^ Tighten to 10 Nm (89 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1587 Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines. ^ Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1588 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1589 Fluid - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission Transmission Fluid Level Check Transmission Fluid Level Check CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler, cooler tubes 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 transmission fluid cooling system. 1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK. 2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the transmission fluid level indicator from the transmission fluid fill plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1590 5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. 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 transmission fluid level must be at the upper level of the crosshatch mark. 7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1591 Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1592 Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill plug. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1593 5. 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 transmission fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. CAUTION: The transmission 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 transmission fluid leaking, the transmission fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. ^ Adding 3.3L (3.5 qt) of clean transmission fluid to the transmission is an initial fill enabling you to start the engine. ^ The cold transmission fluid level range shown in the procedure allows the vehicle to be driven. ^ The vehicle should be driven to allow the transmission fluid temperature to reach 85° C-88° C (185° F-190° F) in order to purge the air from the transmission fluid cooling system. ^ Fill the transmission fluid to the full range on the transmission fluid level indicator at the normal operating range 80° C-85° C (175° F-185° F). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean transmission fluid added to the transmission as an initial fill if: ^ the transmission has been overhauled. ^ a new mechatronic assembly has been installed. ^ the transmission fluid pan or transmission fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean transmission fluid to the transmission through the transmission 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). ^ With the engine running, use the scan tool to monitor transmission fluid temperature and engine speed. 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 transmission fluid level indicator from the transmission fluid fill plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1594 4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 5. Add clean transmission fluid to the cold level location as shown in the illustration. 1 Transmission fluid cold level. 6. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1595 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 transmission fluid 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. 9. Separate the transmission fluid level indicator from the transmission fluid fill plug. 10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1596 11. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. 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 transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the special tool into the transmission fluid fill hole. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1597 2. Fill the special tool with approximately 0.47L (1 pt) of clean transmission fluid. 3. Hang the special tool under the vehicle, upright and close to the transmission. 4. Connect the special tools. ^ Connect the open end of the hose from the special tool onto the special tool from the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1598 5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission. 6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 7. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1599 Removing Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the special tools to extract any excessive transmission fluid. 2. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 3. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1600 Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 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 transmission fluid cooler tubes and install a new transmission fluid cooler before placing the transmission in use. CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the transmission fluid cooling system or transmission could occur. 1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the transmission fluid cooler and tubes. 3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately in the following sequence. 1 Connect the pressure line to the transmission fluid cooler inlet tube. 2 Connect the return line to the transmission fluid cooler outlet tube. 3 Place the outlet end of the return line in the transmission fluid tank reservoir. 4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system. Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler tubes. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 2.7 pts. (1.3L) Rear Differential Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 3.5 pts. (1.7L) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1605 Fluid - Differential: Fluid Type Specifications Front Differential Front Differential Dana 30.............................................................................................................................................M otorcraft SAE 80W-90 Premium Rear Axle Lubricant Part Number......................................................................................................................................... ..XY-80W90-QL(US) / CXY-80W90-1L(CANADA) Specification......................................................................................................................................... .........................................................WSP-M2C197-A Rear Differential Rear Differential Ford 8.8 Inch Ring Gear.................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Part Number......................................................................................................................................X Y-75W-140-QL(US) / CXY-75W140-1L(CANADA) Specification......................................................................................................................................... ........................................WSL-M2C192-A and GL-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1606 Fluid - Differential: Service and Repair Differential Draining and Filling Fluid Drain and Fill 1. Remove both the fill plug and the drain plug. ^ Drain the axle assembly. 2. Clean and install the drain plug. ^ Tighten to 34 Nm (25 lb-ft). 3. Fill the axle with 1.65L (3.5 pt) of axle lubricant to the bottom of the fill plug hole. 4. Clean and install the fill plug. ^ Tighten to 34 Nm (25 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... ................................................. 1.5 Quarts (1.4 Liters) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1611 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid.............................................................................................................................. ...................................Motorcraft Transfer Case Fluid Part Number......................................................................................................................................... ...........................................................................XL-12 Specification......................................................................................................................................... ..........................................................ESP-M2C166-H Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1612 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling 1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: Position a suitable drain pan under the transfer case. Remove the drain plug and drain the fluid. 2. Clean and install the drain plug. ^ To install, tighten to 20 Nm (15 lb-ft). 3. CAUTION: Incorrect fluid fill can result in transfer case failure. NOTE: Fill the transfer case with the vehicle on a level surface. Make sure the fluid is level with the filler opening for the correct fluid level. Clean the area around the fill plug. Remove the fill plug. Using a suitable oil suction gun, fill the transfer case to the correct level with the specified fluid. 4. Clean and install the fill plug. ^ To install, tighten to 15 Nm (11 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ..................................................... 5.7 Liters (6.0 Qt) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1617 Engine Oil: Fluid Type Specifications Engine Oil U.S. ......................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the API Certification mark and meet the requirements of Ford Specification WSS-M2C930-A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Ford Part Name ................................................................................................................................... ................................ Motorcraft MERCON V ATF Ford Part Number ................................................. ............................................................................................................................................. XT-5-QM Ford Specification ................................................................................................................................ ......................................................... MERCON V Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1621 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. Refer to Inspection and Verification. 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 an extended amount of time. Damage to the power steering pump may 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. 10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may 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. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A (Specification) - 0.88 kg (31 oz) (vehicles without auxiliary systems) (Fill Capacity) R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A (Specification) - 1.33 kg (47 oz) (vehicles with auxiliary systems) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1626 Refrigerant: Fluid Type Specifications R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A (Specification) - 0.88 kg (31 oz) (vehicles without auxiliary systems) (Fill Capacity) R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A (Specification) - 1.33 kg (47 oz) (vehicles with auxiliary systems) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Climate Control System PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B (Specification) - 266 ml (9 fl oz) (vehicles without auxiliary systems) (Fill Capacity) PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B (Specification) - 473 ml (16 fl oz) (vehicles with auxiliary systems) (Fill Capacity) Auxiliary Climate Control PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B (Specification) - 47 ml (16 fl oz) (with auxiliary climate control) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1631 Refrigerant Oil: Fluid Type Specifications Climate Control System PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B (Specification) - 266 ml (9 fl oz) (vehicles without auxiliary systems) (Fill Capacity) PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B (Specification) - 473 ml (16 fl oz) (vehicles with auxiliary systems) (Fill Capacity) Auxiliary Climate Control PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B (Specification) - 47 ml (16 fl oz) (with auxiliary climate control) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1640 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1646 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1652 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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: This procedure is only required when a new hydraulic control unit (HCU) is installed. NOTE: When any part of the hydraulic system is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1655 Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter 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 entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1656 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 at least 2 times and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft). 6. Bleed the brake system. Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1657 4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap. ^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in). ^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1658 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure Bleed WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). 1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed new, carry out the Brake System Pressure Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System Bleed Procedure. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1659 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. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 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: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 1660 ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1665 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1666 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1667 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1668 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1669 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1670 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1671 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1672 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1673 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1674 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1675 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1676 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1677 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1683 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1684 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1685 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1686 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1687 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1688 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1689 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1690 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1691 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1692 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1693 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1711 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1712 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1713 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1714 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1715 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1716 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1717 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1718 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1719 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1720 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1721 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1726 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1727 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1728 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1729 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1730 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1731 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1732 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1733 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1734 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1735 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1736 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Fuse Block: Connector Views C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1761 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1762 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1763 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1764 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1765 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1766 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1767 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1768 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1769 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1770 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1771 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1776 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1777 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1778 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1779 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1780 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1781 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1782 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1783 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1784 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1785 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1786 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1789 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1790 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1791 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1792 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1793 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1794 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1797 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1798 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1799 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1800 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1801 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1802 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1803 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1804 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1805 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1806 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1807 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (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. Tire Pressure Monitoring System (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. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate. 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 Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. Tire Pressure Monitoring System (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 not received any 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair MESSAGE CENTER CONFIGURATION Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. - All message center functions are carried out using the single stem reset button in the instrument cluster. 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. - Under no circumstances should the vehicle ever be lifted by the front or rear control arms, halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to bumper covers will occur. - To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. - When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. - Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Jacking Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1822 Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1828 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1829 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1832 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1833 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1834 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1835 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1836 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1837 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Tire Pressure Monitoring System (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. Tire Pressure Monitoring System (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. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate. 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 Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. Tire Pressure Monitoring System (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 not received any 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1846 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1847 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1850 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1851 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1852 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1853 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1854 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1855 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1864 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1865 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1866 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1872 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1873 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1874 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1883 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 1888 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1893 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1894 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1899 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1900 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1906 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 1911 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1916 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1917 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1922 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1923 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1928 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 3. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1929 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1930 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 components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 lb-inch). 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1931 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1940 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1946 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut Axle Nut: Specifications Rear Axle Wheel End Nut Rear Axle Wheel End Nut .................................................................................................................... ................................................ 275 Nm (203 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 1952 Axle Nut: Specifications Rear Axle Halfshaft Nut Rear Axle Halfshaft Nut ....................................................................................................................... ................................................ 275 Nm (203 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 1953 Axle Nut: Specifications Front Axle Wheel End Nut Front Axle Wheel End Nut ................................................................................................................... ................................................ 200 Nm (148 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 1954 Axle Nut: Specifications Front Axle Halfshaft Nut Front Axle Halfshaft Nut ...................................................................................................................... ............................................... 250 Nm (184 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts ........................................................................................................................................................... 135 Nm (100 lb-ft). in a star pattern Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Removal 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Using the special tool, remove the wheel stud. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1960 Installation 1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats against the flange. ^ Discard the wheel nut and washers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1961 Wheel Fastener: Service and Repair Rear Wheel Studs Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1962 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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, or incorrect clamp load and component damage may occur. 1. Remove the wheel and tire. 2. CAUTION: Care must be used when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings can occur. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 3. Remove the brake disc. 4. Remove the parking brake shoe adjuster spring and adjuster. 5. NOTE: The brake shield has an access hole knockout that must be removed to allow for the removal of the wheel stud. Using a suitable punch, remove the access hole cover from the brake shield. 6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle. Using the special tool, press the wheel stud until it makes contact with the edge of the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1963 7. Route the wheel stud through the access hole and discard the wheel stud. Installation 1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side of the wheel extension. ^ Discard the wheel nut and washers. 3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Install a plug into the access hole on the brake shield. 4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake caliper and install the bolts. ^ Tighten to 32 Nm (24 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. - Under no circumstances should the vehicle ever be lifted by the front or rear control arms, halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to bumper covers will occur. - To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. - When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. - Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Jacking Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1967 Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1975 C1452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1976 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 (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1977 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1984 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 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1985 Compression Pressure Limit Chart (Part 2) If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Camshaft Phaser and Sprocket Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 1993 Valve Train Components - Exploded View (Part 2) Removal 1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. 2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. 3. CAUTION: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 1994 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 1995 Installation 1. CAUTION: 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. 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. CAUTION: 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. 4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Camshaft Bearing Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. Camshaft Journal to Bearing Clearance - OHC Engines 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. ^ Subtract the camshaft journal diameter from the camshaft bearing diameter. Camshaft End Play - OHC Engines 1. Using the special tool, measure the 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 a new camshaft and recheck end play. ^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2000 Camshaft Surface Inspection 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. Camshaft Lobe Lift 1. Use an indicator gauge to measure camshaft intake/exhaust lobe lift. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Camshaft Runout Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2001 1. NOTE: Camshaft journals must be within specifications before checking runout. Using the special tool, measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2002 Camshaft: Removal and Replacement Camshaft - LH Camshaft - LH Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2003 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2004 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. 5. Remove the LH CMP sensor and the bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2005 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. CAUTION: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2006 to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step. 9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the special tool in the LH timing chain as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2007 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. 12. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2008 13. CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps. 14. Clean and inspect the LH camshaft bearing caps. ^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2009 15. 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. 16. 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. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight. 3. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2010 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft bearing caps in their original locations. ^ Lubricate the camshaft bearing caps with clean engine oil. ^ Position the front camshaft bearing cap. ^ Position the remaining camshaft bearing caps. ^ Install the bolts loosely. 5. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Remove the special tools. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2011 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes. 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2012 NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. 11. Connect the CMP electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2013 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 lb-ft). ^ Stage 2: Tighten an additional 90 degrees. 13. Install the LH valve cover. Camshaft - RH Camshaft - RH Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2014 Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2015 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2016 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. 5. Remove the bolt and the RH CMP sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2017 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. CAUTION: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2018 to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step. 9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the special tool in the RH timing chain as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2019 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: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2020 13. CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps. 14. Clean and inspect the RH camshaft bearing caps. ^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 15. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2021 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. 16. 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. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight. 3. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2022 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft bearing caps in their original locations. ^ Lubricate the camshaft bearing caps with clean engine oil. ^ Position the front camshaft bearing cap. ^ Position the remaining camshaft bearing caps. ^ Install the bolts loosely. 5. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Remove the special tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2023 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes. 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2024 NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. ^ Tighten to 10 Nm (89 lb-in). 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 new camshaft phaser and sprocket bolt in 2 stages: ^ Stage 1: Tighten to 40 Nm (30 lb-ft). ^ Stage 2: Tighten an additional 90 degrees. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2025 13. Install the RH valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 2029 Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjuster Removal and Installation 1. Remove the camshafts. 2. Remove the remaining roller followers from the cylinder head being serviced. 3. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2033 Rocker Arm Assembly: Service and Repair Camshaft Roller Follower Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2034 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2035 Removal 1. Depending on the 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, compress the valve spring and remove the camshaft roller follower. 4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower. Installation 1. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Lubricate the roller follower with clean engine oil. Using the special tool, compress the valve spring and install the camshaft roller follower. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2036 2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve being serviced, install the LH or RH valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2041 C1452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2042 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 (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2043 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 in) Bearing-to-crankshaft clearance ................................................................................................................................. 0.024-0.066 mm (0.0009-0.0026 in) Side clearance ...................................................................................................... .................................................................. 0.5-0.15 mm (0.02-0.006 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2048 Connecting Rod Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects: 1 Cratering - fatigue failure 2 Spot polishing - incorrect seating 3 Imbedded dirty engine oil 4 Scratching - dirty engine oil 5 Base exposed - poor lubrication 6 Both edges worn - journal damaged 7 One edge worn - journal tapered or bearing not seated Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2049 Connecting Rod Bearing: Service and Repair 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts Discard the bolts. First pass ............................................................................................................................................. .................................................... 43 Nm (32 lb-ft). Final pass ............................................................ ..................................................................................................................... Tighten an additional 105° Connecting Rod Clearance-to-pin ......................................................................................................................................................... 0.009-0.023 mm (0.0004-0.0009 in) Pin bore diameter ................................................................................................................................................... 22.012-22.024 mm (0.8666-0.8671 in) Length (center-to-center) ....................................................... ............................................................................................................. 150.7 mm (5.933 in) Maximum allowed bend ....................................................................................................................... ......................................... ± 0.038 mm (0.0015 in) Maximum allowed twist (a) ............................................................................................................................................................ ± 0.05 mm (0.0020 in) Bearing bore diameter (with assembled liners) ...................................................................................................... 53.049-53.027 mm (2.0885-2.0877 in) Bearing-to-crankshaft clearance ................................................................................................................................. 0.024-0.066 mm (0.0009-0.0026 in) Side clearance ...................................................................................................... .................................................................. 0.5-0.15 mm (0.02-0.006 in) (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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2053 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. Connecting Rod to Crankshaft Side Clearance 1. Measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification. Connecting Rod Bushing Diameter 1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2054 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2055 Connecting Rod-to-Piston Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Connecting Rod Bearing Journal-to-Bearing Clearance 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2056 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 and washer. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ............................................................................................................................................ Loosen 360° Third pass ................................................................................................................................... ............................................................ 50 Nm (37 lb-ft). Final pass .................................................... ............................................................................................................................... Tighten an additional 90° Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Vertical Main Bearing Cap Fasteners Discard the fasteners. First pass ............................................................................................................................................. .................................................... 40 Nm (30 lb-ft). Final pass ............................................................ ....................................................................................................................... Tighten an additional 90° Jack Screws Discard the screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2063 First pass ............................................................................................................................................. ..................................................... 5 Nm (44 lb-in). Final pass ............................................................ .................................................................................................................................... 10 Nm (89 lb-in). Side Bolts ............................................................................................................................................ ....................................................... 21 Nm (15 lb-ft). Discard the bolts. Crankshaft Main bearing journal Diameter .......................................................................................................................................................... 67.481-67.505 mm (2.6567-2.6576 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2064 Maximum taper .................................................................................................................................... ...................................... 0.004 mm (0.0002 in) Maximum out-of-round ....................................................................................................................... 0.0075 mm (0.0003 in) between cross sections Clearance-to-cylinder block ................................................................................................................................. 0.048-0.024 mm (0.0019-0.0009 in) Connecting rod journal Diameter .......................................................................................................................................................... 53.003-52.983 mm (2.0867-2.0859 in) Maximum taper ...................................................................... .................................................................................................... 0.004 mm (0.0002 in) Maximum out-of-round ....................................................................................................................... 0.0075 mm (0.0003 in) between cross sections Maximum end play .................................................................................................................................................... 0.075-0.377 mm (0.0030-0.0148 in) Main bearing bore inside diameter ............................................................................................................................. 72.400-72.424 mm (2.850-2.851 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2065 Crankshaft Main Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects: 1 Cratering - fatigue failure 2 Spot polishing - incorrect seating 3 Imbedded dirty engine oil 4 Scratching - dirty engine oil 5 Base exposed - poor lubrication 6 Both edges worn - journal damaged 7 One edge worn - journal tapered or bearing not seated Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 in) Maximum taper ...................................................................... .................................................................................................... 0.004 mm (0.0002 in) Maximum out-of-round ....................................................................................................................... 0.0075 mm (0.0003 in) between cross sections Clearance-to-cylinder block ................................................................................................................................. 0.048-0.024 mm (0.0019-0.0009 in) Connecting rod journal Diameter .......................................................................................................................................................... 53.003-52.983 mm (2.0867-2.0859 in) Maximum taper ...................................................................... .................................................................................................... 0.004 mm (0.0002 in) Maximum out-of-round ....................................................................................................................... 0.0075 mm (0.0003 in) between cross sections Maximum end play .................................................................................................................................................... 0.075-0.377 mm (0.0030-0.0148 in) Main bearing bore inside diameter ............................................................................................................................. 72.400-72.424 mm (2.850-2.851 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2069 Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions. 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. Crankshaft Main Bearing Journal-to-Bearing Clearance 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. 3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. 4. Verify the crankshaft journal clearance. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2070 Crankshaft End Play 1. Using the Dial Indicator Gauge, measure the 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. Crankshaft Runout 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the Dial Indicator Gauge 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2071 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Block Heater Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the cooling system. 3. Disconnect the block heater power cable. 4. NOTE: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the screw and remove the block heater. ^ To install, tighten to 4 Nm (35 lb-in). 5. Clean and inspect the engine block mating surface. Lubricate the block heater seal and the cylinder block hole with clean engine coolant. 6. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or the cable may be damaged. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 and washer. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ............................................................................................................................................ Loosen 360° Third pass ................................................................................................................................... ............................................................ 50 Nm (37 lb-ft). Final pass .................................................... ............................................................................................................................... Tighten an additional 90° Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2078 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2079 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cooling fan shroud. For additional information, refer to Cooling System. 3. Remove the accessory drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 4. Remove and discard the crankshaft pulley bolt and washer. 5. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. 2. Using the special tool, install the crankshaft pulley. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2080 3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 lb-ft). ^ Stage 2: Loosen 360 degrees. ^ Stage 3: Tighten to 50 Nm (37 lb-ft). ^ Stage 4: Tighten an additional 90 degrees. 4. Install the accessory drive belt. 5. Install the cooling fan shroud. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) (uncoated) Grade 1 ............................................................................................................................................................ 90.182-90.167 mm (3.5504-3.5499 in) Grade 2 ............................................................................................................................................................. 90.196-90.179 mm (3.551-3.5503 in) Grade 3 ............................................................................................................................................................. 90.208-90.193 mm (3.5515-3.551 in) Clearance-to-cylinder bore (at grade size) ................................................................................................................. 0.017-0.047 mm (0.0007-0.0019 in) Ring end gap Top ...................................................................................................................................................... ......................... 0.15-0.30 mm (0.006-0.012 in) Intermediate ............................................................................................................................................................. 0.25-0.50 mm (0.0098-0.0197 in) Oil control ....................................................................................... ......................................................................... 0.15-0.65 mm (0.0059-0.0256 in) Ring groove width Top ...................................................................................................................................................... ..................... 1.52-1.54 mm (0.0598-0.0606 in) Intermediate ............................................................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 in) Oil control ............................................................................................................................................................ 3.030-3.056 mm (0.1193-0.1203 in) Ring width Top and intermediate ............................................................................................................................................... 1.50-1.48 mm (0.0590-0.0582 in) Ring-to-groove clearance Top ...................................................................................................................................................... ................. 0.020-0.060 mm (0.0008-0.0020 in) Intermediate ......................................................................................................................................................... 0.020-0.060 mm (0.0008-0.0020 in) Pin bore diameter ............................................................................................................................................... 22.0125-22.0175 mm (0.8666-0.8668 in) Pin Diameter ...................................................................................................................................................... 22.0010-22.0030 mm (0.8662-0.8663 in) Length ................................................................................ ............................................................................................................. 61.8 mm (2.433 in) Fit-to-piston ....................................................................................................................................................... 0.0095-0.023 mm (0.0004-0.0009 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston Inspection 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 Bore Diameter 1. WARNING: Since the retainer ring has a tendency to spring out, cover the end of the pin bore with a hand or shop rag when removing the ring. Wear eye protection. Failure to follow these instructions may result in serious personal injury. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2086 Piston Diameter 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of the piston at the point indicated. Piston To Cylinder Bore Clearance 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2087 2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot or specific size grade on a new piston indicates the position within the size range. Choose the piston with the correct paint color or specific size grade. Piston Ring End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. NOTE: Piston rings should not be transferred from one piston to another. NOTE: The cylinder bore must be within specification for taper and out-of-round. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2088 Piston Ring-to-Groove Clearance 1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. Piston Pin Diameter 1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2090 Piston: Overhaul Piston 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. Position the connecting rod in the piston. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2091 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings End gap Top ...................................................................................................................................................... ......................... 0.15-0.30 mm (0.006-0.012 in) Intermediate ............................................................................................................................................................. 0.25-0.50 mm (0.0098-0.0197 in) Oil control ....................................................................................... ......................................................................... 0.15-0.65 mm (0.0059-0.0256 in) Ring groove width Top ...................................................................................................................................................... ..................... 1.52-1.54 mm (0.0598-0.0606 in) Intermediate ............................................................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 in) Oil control ............................................................................................................................................................ 3.030-3.056 mm (0.1193-0.1203 in) Ring width Top and intermediate ............................................................................................................................................... 1.50-1.48 mm (0.0590-0.0582 in) Ring-to-groove clearance Top ...................................................................................................................................................... ................. 0.020-0.060 mm (0.0008-0.0020 in) Intermediate ......................................................................................................................................................... 0.020-0.060 mm (0.0008-0.0020 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2105 Rocker Arm Assembly: Service and Repair Camshaft Roller Follower Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2106 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2107 Removal 1. Depending on the 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, compress the valve spring and remove the camshaft roller follower. 4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower. Installation 1. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Lubricate the roller follower with clean engine oil. Using the special tool, compress the valve spring and install the camshaft roller follower. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Page 2108 2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve being serviced, install the LH or RH valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2113 Removal 1. Remove the LH ignition coils. 2. Remove the bolt and position the oil level indicator and tube aside. 3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 4. Disconnect the PCV hose from the valve cover. 5. Remove the nut and position the cooling fan wiring harness bracket aside. 6. Disconnect the 2 pin-type retainers from the valve cover. 7. Disconnect the variable camshaft timing (VCT) solenoid electrical connector. 8. Detach the wiring harness retainers from the valve cover studs. 9. Disconnect the EVAP canister purge valve electrical connector. 10. Disconnect the EVAP canister-to-EVAP canister purge valve EVAP hose from the EVAP canister purge valve. 11. Loosen the 10 bolts and remove the LH valve cover and gasket. ^ Discard the gasket. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2114 Clean the gasket mating surfaces. ^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Clean the valve cover gasket groove in the valve cover with soap and water or a suitable solvent. 2. Install a new gasket on the LH valve cover. 3. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure may cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 4. Position the LH valve cover with a new gasket and tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 5. Connect the EVAP canister-to-EVAP canister purge valve EVAP hose to the EVAP canister purge valve. 6. Connect the EVAP canister purge valve electrical connector. 7. Attach the wiring harness retainers to the valve cover studs. 8. Connect the VCT solenoid electrical connector. 9. Connect the 2 pin-type retainers to the valve cover. 10. Position the cooling fan wiring harness bracket and install the nut. ^ Tighten to 25 Nm (18 lb-ft). 11. Connect the PCV hose to the valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2115 12. Connect the EVAP tube to the intake manifold. 13. Position the oil level indicator tube and install the bolt. ^ Tighten to 10 Nm (89 lb-in). 14. Install the LH ignition coils. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2116 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2117 Removal 1. Remove the air cleaner (ACL) and the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2118 2. Remove the RH ignition coils. 3. Disconnect the engine wiring harness from the PCM. ^ Disconnect the 2 PCM electrical connectors. ^ Disconnect the in-line electrical connector. ^ Detach the wiring harness retainer from the PCM bracket and position the wiring harness aside. 4. Disconnect the RH variable camshaft timing (VCT) oil control solenoid electrical connector. 5. Detach the 2 wiring harness retainers from the RH valve cover studs. 6. Detach the wiring harness pin-type retainer from the front of the RH valve cover. 7. Detach the heater hose retainer from the RH valve cover. 8. Disconnect the crankcase breather tube from the RH valve cover. 9. Loosen the 9 RH valve cover bolts and remove the RH valve cover and the RH valve cover gasket. ^ Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the gasket mating surfaces. ^ Clean the valve cover mating surface of the RH cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Clean the RH valve cover gasket groove with soap and water or a suitable solvent. 2. Install a new gasket on the RH valve cover. 3. NOTE: If the RH valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure may cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the RH cylinder head. 4. Position the RH valve cover with a new gasket on the cylinder head and tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2119 5. Connect the crankcase breather tube to the RH valve cover. 6. Attach the heater hose retainer to the RH valve cover. 7. Attach the wiring harness pin-type retainer to the front of the RH valve cover. 8. Attach the wiring harness retainers to the RH valve cover studs. 9. Connect the RH VCT oil control solenoid electrical connector. 10. Connect the engine wiring harness to the PCM. ^ Position the wiring harness and attach the wiring harness pin-type retainer to the PCM bracket. ^ Connect the in-line electrical connector. ^ Connect the 2 PCM electrical connectors. 11. Install the RH ignition coils. 12. Install the air cleaner and the air cleaner outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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, install a new cylinder head assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 NOTE: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found. 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 a valve seat runout gauge to check valve seat runout. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Page 2126 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures Valve Spring Installed Length 1. Measure the installed length of each valve spring. Valve Spring Free Length 1. Measure the free length of each valve spring. Valve Spring Squareness 1. Measure the out-of-square on each valve spring. ^ Turn the valve spring and observe the space between the top of the valve spring and the square. Valve Spring Strength Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2131 1. Use the special tool to check the valve spring for correct strength at the specified valve spring length. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2132 Valve Spring: Removal and Replacement Valve Springs Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2133 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2134 Removal 1. Depending on the valve spring being serviced, remove the LH or RH valve cover. 2. Remove the spark plug. 3. Rotate the crankshaft until the piston for the valve spring 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. 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 the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. Using the special tool, compress the valve spring and remove the valve spring retainer keys. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2135 7. Remove the valve spring retainer and the valve spring. 8. Inspect the valve spring. Installation 1. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the special tool, compress the valve spring and install the camshaft roller follower. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2136 4. Install the spark plug. 5. Depending on the valve spring being serviced, install the LH or RH valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 the following valve areas: 1 The end of the stem for grooves or scoring. 2 The valve face and the edge for pits, grooves or scores. 3 The valve head for signs of burning, erosion, warpage and cracking. 4 The valve margin for wear. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter Valve: Service and Repair Valve Stem Diameter Valve Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 2142 Valve: Service and Repair Valve Stem to Valve Guide Clearance Valve Stem to Valve Guide Clearance NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide. 2. Move the clearance gauge toward the indicator and zero the indicator. Move the clearance gauge away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2152 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2158 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2159 Drive Belt: Diagrams Component Locations - 4.6L (3V) Component Locations - 4.6L (3V) (Part 1) Component Locations - 4.6L (3V) (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart Belt Tensioner With Belt Length Indicator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2162 3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service limit. Install a new belt as necessary. 4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 5. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2163 6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be considered acceptable. If cracks exceed this standard, install a new belt. V-Ribbed Serpentine Belt With Piling 7. 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. V-Ribbed Serpentine Belt With Chunks of Rib Missing 8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2164 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2165 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2166 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt - Noise/Flutter CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2167 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. 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 from the tensioner. Carry out the following tests: ^ Using the release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. ^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. ^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2168 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2169 Drive Belt: Service and Repair Accessory Drive Belt - 4.6L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V) Removal and Installation 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2170 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 - 4.6L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V) Removal and Installation 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Page 2174 3. Remove the bolts and the accessory drive belt tensioner. ^ To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures Engine Mount: Procedures Powertrain/Drivetrain Mount Neutralizing NOTE: Refer to the appropriate procedure for special instructions on loosening and tightening mount fasteners. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may occur. Move the vehicle in forward and reverse 0.6-1.2 m (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2179 Engine Mount: Removal and Replacement Engine Support Insulators Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2181 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. 2. Remove the engine cooling fan. For additional information, refer to Cooling System. 3. Remove the throttle body (TB). For additional information, refer to Fuel Delivery and Air Induction. 4. Remove the generator. For additional information, refer to Alternator. 5. Disconnect the PCV valve hose from the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2182 6. Remove the bolts and position the heated PCV fitting aside. 7. Disconnect the evaporative emission (EVAP) hose from the intake manifold. 8. Remove the 5 pushpins and the splash shield. 9. Remove the RH engine support insulator upper nuts. ^ To install, tighten to 90 Nm (66 lb-ft). 10. Remove the LH engine support insulator through bolt. ^ To install, tighten to 103 Nm (76 lb-ft). 11. Install the special tools and raise the engine approximately 70 mm (2.75 in). RH side 12. Remove the RH engine support insulator lower nut. ^ To install, tighten to 90 Nm (66 lb-ft). 13. Remove the RH engine support insulator. Four wheel drive (4WD) vehicles 14. Remove the stabilizer bar bracket bolts and allow the stabilizer bar to hang freely. ^ To install, tighten to 55 Nm (41 lb-ft). 15. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury. Support the differential housing with a suitable jack stand. 16. Disconnect the vent hose from the differential housing vent tube. 17. CAUTION: Any time bolts, washers, spacers or nuts are loosened in the differential support for any reason, install new components to prevent damage. Remove and discard the 3 bolts and 3 flagnuts. ^ To install, tighten to 66 Nm (49 lb-ft). 18. Lower the differential housing approximately 25 mm (1 in). LH side 19. Remove the LH engine support insulator nut. ^ To install, tighten to 90 Nm (66 lb-ft). 20. Remove the engine support insulator. 21. To install, reverse the removal procedure. ^ If equipped, install new differential housing bolts and flagnuts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2191 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 for Idler Pulley: > 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2197 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 2198 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley - 4.6L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V) Removal and Installation 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the drive belt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 2199 3. NOTE: The 4.6L (3V) has 3 idler pulleys, an upper RH, an upper LH and a lower LH. Remove the bolt and the accessory drive belt idler pulley. ^ To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure minimum at 2,000 rpm (engine at normal operating temperature) .......................................................................................... 517 kPa (75 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 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 lb-in). 3. Remove the oil level indicator and tube from the cylinder block. 4. Remove and discard the O-ring seal. 5. NOTE: Install a new oil level indicator tube O-ring seal and lubricate it with clean engine oil prior to installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 ............................................................................................................................................ ..................................................... 5.7 Liters (6.0 Qt) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2211 Engine Oil: Fluid Type Specifications Engine Oil U.S. ......................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the API Certification mark and meet the requirements of Ford Specification WSS-M2C930-A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine cooling system. For additional information, refer to Cooling System. 3. Drain the engine oil. ^ Install the drain plug and tighten to 23 Nm (17 lb-ft). 4. Disconnect the engine oil pressure switch electrical connector. 5. Disconnect the lower radiator hose and position it aside. 6. Remove and discard the engine oil filter. ^ To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2215 - Using an oil filter strap wrench, tighten the filter an additional 270 degrees. 7. Remove the 4 bolts and the oil filter adapter. ^ To install, tighten to 25 Nm (18 lb-ft). 8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil filter adapter gasket. ^ Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Inspect the mating surfaces. 9. To install, reverse the removal procedure. ^ Fill the engine with clean engine oil. 10. Fill and bleed the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 lb-in). Second pass ........................................................ ..................................................................................................................................... 20 Nm (15 lb-ft). Final pass ................................................................................................................................... ................................................ Tighten an additional 60° Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2219 Oil Pan: Service and Repair Oil Pan Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2220 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2221 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the front axle, if equipped. 3. Remove the stabilizer bar. 4. Remove the drain plug and drain the engine oil. Install the drain plug when finished. ^ Tighten to 23 Nm (17 lb-ft). 5. Remove the nut and position the power steering pressure (PSP) hose bracket aside. 6. Remove the nut and position the battery cable bracket aside. 7. Disconnect the oil temperature sensor electrical connector. 8. Remove the bolts and the oil drain splash shield. 9. If equipped with a block heater, detach the block heater wiring harness retainers from the LH side oil pan bolts. 10. Remove the bolts, the oil pan and the gasket. ^ Discard the gasket. Installation 1. 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. Failure to follow these directions can cause future oil leaks. Clean and inspect the sealing surfaces with silicone gasket remover, metal surface prep, and a plastic scraper. Follow the directions on the packaging. 2. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the sealant must be removed and the sealing surfaces cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Apply silicone gasket and sealant in 2 places as shown. 3. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the sealant must be removed and the sealing surfaces cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2222 Apply silicone gasket and sealant in 2 places as shown. 4. Position a new oil pan gasket and the oil pan and install the bolts finger-tight. 5. Tighten the bolt in 3 stages in the sequence shown. ^ Stage 1: Tighten to 2 Nm (18 lb-in). ^ Stage 2: Tighten to 20 Nm (15 lb-ft). ^ Stage 3: Tighten an additional 60 degrees. 6. If equipped with a block heater, attach the block heater wiring harness retainers to the LH oil pan bolts. 7. Position the oil drain splash shield and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). 8. Connect the oil temperature sensor electrical connector. 9. Attach the battery cable bracket and install the nut. ^ Tighten to 10 Nm (89 lb-in). 10. Attach the PSP hose bracket and install the nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2223 ^ Tighten to 10 Nm (89 lb-in). 11. Install the stabilizer bar. 12. Install the front axle, if equipped. 13. Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2227 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2228 C103 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 2232 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 2233 Removal 1. Remove the oil pan. 2. Remove the bolts and the oil pump screen and pickup tube. Installation 1. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal 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 seal. Lubricate the O-ring seal 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 lb-in). ^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 2234 2. Install the oil pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure minimum at 2,000 rpm (engine at normal operating temperature) .......................................................................................... 517 kPa (75 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold Bolts First pass ............................................................................................................................................. ..................................................... 2 Nm (18 lb-in). Final pass ............................................................ .................................................................................................................................... 10 Nm (89 lb-in). Throttle Body Bolts .............................................................................................................................. .................................................... 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2245 Intake Manifold: Service and Repair Intake Manifold Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2246 Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 3. Remove the fuel rail and injectors. For additional information, refer to Fuel Delivery and Air Induction. 4. Disconnect the electronic throttle body (TB) electrical connector. 5. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 6. Disconnect the throttle position (TP) sensor electrical connector. 7. Disconnect the PCV hose from the heated PCV fitting on the intake manifold. 8. Remove the bolts and position the heated PCV fitting aside. ^ Remove and discard the O-ring seal. 9. Detach the wiring harness retainers from the intake manifold. 10. Disconnect the charge motion control valve (CMCV) electrical connector. 11. Remove the bolts and position the intake manifold forward. 12. Disconnect the brake booster vacuum hose from the rear of the intake manifold. 13. Disconnect the vacuum hose from the rear of the intake manifold. 14. Remove the intake manifold and the gaskets. ^ Discard the gaskets. 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 gaskets. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care during the installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2247 Using new intake manifold gaskets, position the intake manifold. 2. Connect the vacuum hose to the rear of the intake manifold. 3. Connect the brake booster hose to the rear of the intake manifold. 4. Install the intake manifold bolts and tighten the bolts in the sequence shown in 2 stages. ^ Stage 1: Tighten to 2 Nm (18 lb-in). ^ Stage 2: Tighten to 10 Nm (89 lb-in). 5. Connect the CMCV electrical connector. 6. Attach the wiring harness retainers to the intake manifold. 7. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 8. Connect the PCV hose to the heated PCV fitting on the intake manifold. 9. Connect the TP sensor electrical connector. 10. Connect the EVAP hose to the intake manifold. 11. Connect the electronic TB electrical connector. 12. Install the fuel rail and injectors. 13. Install the air cleaner outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2253 Removal 1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Using the special tools, remove the crankshaft oil slinger. ^ Discard the crankshaft oil slinger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2254 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 the crankshaft rear seal. 2. Using the special tools, install the crankshaft rear oil slinger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2255 3. Install the engine-to-transmission spacer plate. 4. Install the flexplate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2256 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2257 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2258 Removal 1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Remove the oil pan. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2259 NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surfaces. 2. NOTE: The crankshaft rear seal retaining plate does not have a sealant groove. Gasket maker must be applied to the crankshaft rear seal retainer plate mating surface on the engine block. Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the engine block. 3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 4. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the special tools, install the crankshaft rear seal. 5. Using the special tools, install the crankshaft rear oil slinger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2260 6. Install the oil pan. 7. Install the engine-to-transmission spacer plate. 8. Install the flexplate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2264 Removal 1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front seal. Installation 1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2265 2. Using the special tools, install the crankshaft front seal. 3. Install the crankshaft pulley. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2269 Valve Train Components - Exploded View (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2270 Removal 1. Depending on the valve seal being serviced, remove the LH or RH valve cover. 2. Remove the spark plug. 3. Rotate the crankshaft until the piston for the valve seal 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. 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 the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. Using the special tool, compress the valve spring and remove the valve spring retainer keys. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2271 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. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. 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 their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2272 NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. 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. 6. Install the spark plug. 7. Depending on the valve seal being serviced, install the LH or RH valve cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2277 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2278 C103 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: Service and Repair Camshaft Phaser and Sprocket Valve Train Components - Exploded View (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 2286 Valve Train Components - Exploded View (Part 2) Removal 1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. 2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. 3. CAUTION: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 2287 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 2288 Installation 1. CAUTION: 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. 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. CAUTION: 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. 4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 and washer. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ............................................................................................................................................ Loosen 360° Third pass ................................................................................................................................... ............................................................ 50 Nm (37 lb-ft). Final pass .................................................... ............................................................................................................................... Tighten an additional 90° Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolts ............................................................................................................. .................................................... 25 Nm (18 lb.ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Front Fasteners ...................................................................................................................................................... 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2298 Engine Front Cover Lower Fasteners First pass ............................................................................................................................................. .................................................... 20 Nm (15 lb-ft). Final pass ............................................................ ....................................................................................................................... Tighten an additional 60° Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2299 Timing Cover: Service and Repair Engine Front Cover Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2300 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2301 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2302 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the engine oil. ^ To install, tighten to 23 Nm (17 lb-ft). 3. Remove the cooling fan shroud. For additional information, refer to Cooling System. 4. Remove the RH side idler pulley. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 5. Remove the RH valve cover. 6. Remove the LH valve cover. 7. Remove the nut and position the RH radio interference capacitor aside. 8. Disconnect the RH camshaft position (CMP) sensor electrical connector. 9. Remove the nut and the cooling fan wiring harness bracket. 10. Remove the nut and position the LH radio interference capacitor aside. 11. Disconnect the LH CMP sensor electrical connector. 12. Remove the bolts and the coolant pump pulley. 13. Remove the nuts and detach the battery cable bracket from the power steering pump stud bolts. 14. Detach the wiring harness retainer from the power steering pump stud bolt. 15. Remove the stud bolts and position the power steering pump aside. ^ Support the power steering pump with a length of mechanic's wire. 16. Remove the nut and detach the power steering pressure (PSP) hose bracket from the battery cable bracket. 17. Remove the nut and detach the battery cable bracket from the engine front cover. 18. Remove the nut and detach the transmission cooler tube bracket from the engine front cover. 19. Disconnect the crankshaft position (CKP) sensor electrical connector. 20. Remove the crankshaft pulley bolt and washer. ^ Discard the crankshaft pulley bolt. 21. Using the special tool, remove the crankshaft pulley. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2303 22. Using the special tool, remove the crankshaft front seal. ^ Discard the crankshaft front seal. 23. Remove the oil pan-to-engine front cover bolts. 24. Remove the engine front cover bolts and stud bolts. 25. Remove the engine front cover from the engine front cover-to-cylinder block dowel. ^ Remove and discard the engine front cover gaskets. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the mating surfaces with silicone gasket remover, metal surface prep and a plastic scraping tool. Follow the directions on the packaging. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block mating surface and the oil pan-to-cylinder block mating Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2304 surface at the locations shown. 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 the sequence shown to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2305 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2306 5. Loosely install the oil pan-to-engine front cover bolts, then tighten the bolts in 2 stages in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten an additional 60 degrees. 6. Lubricate the engine front cover and a new crankshaft front seal inner lip with clean engine oil. 7. Using the special tools, install the crankshaft front seal. 8. 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. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket sealant to the Woodruff key slot in the crankshaft pulley. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2307 9. Using the special tool, install the crankshaft pulley. 10. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 lb-ft). ^ Stage 2: Loosen 360 degrees. ^ Stage 3: Tighten to 50 Nm (37 lb-ft). ^ Stage 4: Tighten an additional 90 degrees. 11. Connect the CKP sensor electrical connector. 12. Attach the transmission cooler tube bracket to the engine front cover and install the nut. ^ Tighten to 12 Nm (9 lb-ft). 13. Attach the battery cable bracket to the front cover and install the nut. ^ Tighten to 10 Nm (89 lb-in). 14. Attach the PSP hose bracket to the battery cable bracket and install the nut. ^ Tighten to 10 Nm (89 lb-in). 15. Position the power steering pump and install the stud bolts. ^ Tighten to 25 Nm (18 lb-ft). 16. Attach the wiring harness retainer to the power steering pump stud bolt. 17. Position the battery cable bracket on the power steering pump stud bolts and install the nuts. ^ Tighten to 10 Nm (89 lb-in). 18. Position the coolant pump pulley and install the bolts. ^ Tighten the bolts to 25 Nm (18 lb-ft). 19. Connect the LH CMP sensor electrical connector. 20. Position the LH radio interference capacitor and install the nut. ^ Tighten to 25 Nm (18 lb-ft). 21. Position the cooling fan wiring harness bracket and install the nut. 22. Connect the RH CMP sensor electrical connector. 23. Position the RH radio interference capacitor and install the nut. ^ Tighten to 25 Nm (18 lb-ft). 24. Install the LH valve cover. 25. Install the RH valve cover. 26. Install the RH side idler pulley. 27. Install the cooling fan shroud. 28. Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2313 C1452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2314 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 (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2315 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 (KOEO).............................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2323 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 4.6L shown, 4.0L similar. Install the special tool in line between the fuel supply tube and fuel rail. 3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2324 6. NOTE: - 4.6L shown, 4.0L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 630 - 850 RPM ................................................................................................ ...................................................................................................... Hot Idle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2332 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2333 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing..............................................................................................................................................10 degrees before top dead center (BTDC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 2347 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2352 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2353 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2354 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2355 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2356 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2357 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2358 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2359 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2360 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2361 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2362 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap (not adjustable)............................................................................................................ ...................................1.02-1.28 mm (0.040-0.050 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2365 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2366 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type (early build - black coil boot)....................................................................................... ....................................................................PZT-14F Spark plug type (late build - brown coil boot).... ....................................................................................................................................................HJFS -24FP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2367 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. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2368 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(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2369 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2370 Spark Plug: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2371 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2375 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 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2376 Compression Pressure Limit Chart (Part 2) If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant Pump Bolts ............................................................................................................................. ..................................................... 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2383 Water Pump: Service and Repair Coolant Pump - 4.6L (3V) Removal and Installation 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 4. Remove the bolts and the coolant pump pulley. ^ To install, tighten to 25 Nm (18 lb-ft). 5. Remove the bolts and the coolant pump. ^ To install, tighten to 25 Nm (18 lb-ft). 6. Remove and discard the coolant pump O-ring. 7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2384 tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old O-ring. Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the directions on the packaging. 8. To install, reverse the removal procedure. ^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. .............................................. 13.9 quarts (13.2 liters) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2390 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford Part Number ................................................................................................................................ .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Note: Add the coolant type originally equipped in your vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2394 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2395 Removal and Installation 1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 4. Disconnect the electrical connector. 5. Loosen the generator nuts. ^ To install, tighten to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2396 6. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket and wiring harness aside as an assembly. ^ To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. ^ To install, tighten to 10 Nm (89 lb-in). 11. To install, reverse the removal procedure. ^ Install new gaskets. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Expansion Tank CAUTION: Allow the engine to cool before removing the coolant expansion tank. The radiator draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the radiator will draw air into the system, resulting in possible engine damage. 1. Disconnect the coolant overflow hose. 2. If equipped, detach the mass air flow (MAF) sensor wiring harness retainer. 3. Remove the bolts and the coolant expansion tank. ^ To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. ^ Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation Radiator Cooling Fan Motor: Description and Operation FAN CONTROL The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure) to determine engine cooling fan needs. For variable speed electric fan(s): Edge/MKX, Taurus/Taurus X/Sable, 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): PCM FC Output State For Cooling Fan Speeds 2.3L Escape: 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 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan Removal and Installation Vehicle equipped with a 4.6L (3V) 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 lb-in). 4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 lb-in). 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2410 7. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 lb-ft). 8. Remove the bolts and separate the fan from the fan clutch. ^ To install, tighten to 7 Nm (62 lb-in). 9. If necessary, unclip and disconnect the fan clutch wiring harness. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams C1158 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2414 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2415 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2423 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2424 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2425 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Shroud Removal and Installation Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 lb-in). 4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 lb-in). 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2429 7. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 lb-ft). 8. Remove the bolts and the lower fan shroud. ^ To install, tighten to 7 Nm (62 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair HEATER CONTROL VALVE Removal and Installation Vehicles with 4.0L and oil cooler, without auxiliary climate control 1. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect the heater control valve vacuum hose. Vehicles with 4.0L and oil cooler, without auxiliary climate control 5. Remove the heater control valve bolt. All vehicles 6. Remove the heater control valve. 7. NOTE: Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. 8. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection Heater Core: Testing and Inspection HEATER CORE 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the heater control valve may be stuck closed. - the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Page 2436 5. If a leak is observed, replace the heater core. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 pressure leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3. Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6. Remove the 3 housing brace screws. 7. Remove the housing brace. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2439 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. 10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2440 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2441 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Release the 2 heater hose clamps and disconnect the heater hoses. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2442 4. Remove the rear quarter trim panel. 5. Remove the 2 auxiliary line floorpan bracket nuts. 6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket. Remove the 4 line bracket screws and the line bracket. 7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts and auxiliary housing nut. - To install, tighten to 6 Nm (53 lb-in). 9. Disconnect the 2 auxiliary actuator electrical connectors. 10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15. Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the auxiliary heater core. 18. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only if needed. 19. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2447 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2448 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2453 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2455 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2456 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. Vehicles equipped with a 4.6L (3V) engine 3. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 4. Remove the coolant expansion tank. 5. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 lb-in). 6. Release the clamp and disconnect the upper radiator hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Detach the lower radiator hose retainer from the lower fan shroud. 9. Detach the transmission cooler hose retainer from the RH radiator support bracket. 10. Remove the 4 lower radiator air deflector pushpins. 11. Remove the latch assemblies from the transmission cooler tubes. 12. Using the special tool, disconnect the transmission cooler tubes. 13. Remove the upper fan shroud bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2457 14. Disconnect the fan clutch electrical connector. 15. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 lb-in). 16. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 lb-ft). 17. Remove the bolts and the lower fan shroud. 18. Detach the A/C tube from the retainer on the radiator support bracket. 19. Remove the radiator support bracket-to-radiator support bracket bolts. ^ To install, tighten to 15 Nm (11 lb-ft). 20. Remove the radiator top seal. 21. NOTE: Do not remove the A/C condenser seals. Deflect the A/C condenser seals and remove the A/C condenser-to-radiator support bracket bolts. ^ Position the A/C condenser aside. ^ To install, tighten to 12 Nm (9 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2458 22. Remove the radiator and the radiator support brackets as an assembly. 23. Remove the bolts and separate the radiator support brackets and the radiator. ^ To install, tighten to 12 Nm (9 lb-ft). 24. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2470 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2471 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2472 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperatures Starts to open ............................................................................. ........................................................................................................ 87-91° C (189-196° F) Fully open ..................................................................................................................................................... ................................................ 100° C (212° F) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2476 Thermostat: Service and Repair Thermostat - 4.6L (3V) Removal and Installation 1. Drain the cooling system. 2. Remove the throttle body. For additional information, refer to Fuel Delivery and Air Induction. 3. Disconnect the fuel vapor tube. 4. Remove the bolts and position the thermostat housing cover aside. 5. Remove the O-ring seal and the thermostat. Installation 1. Install the thermostat with the spring facing down. 2. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal, if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2477 Install the O-ring seal. 3. Position the thermostat housing cover and the bolts. ^ Tighten to 10 Nm (89 lb-in). 4. Connect the fuel vapor hose. 5. Install the throttle body. 6. Fill and bleed the cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant Pump Bolts ............................................................................................................................. ..................................................... 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2481 Water Pump: Service and Repair Coolant Pump - 4.6L (3V) Removal and Installation 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 4. Remove the bolts and the coolant pump pulley. ^ To install, tighten to 25 Nm (18 lb-ft). 5. Remove the bolts and the coolant pump. ^ To install, tighten to 25 Nm (18 lb-ft). 6. Remove and discard the coolant pump O-ring. 7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2482 tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old O-ring. Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the directions on the packaging. 8. To install, reverse the removal procedure. ^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Catalyst Efficiency Monitor For most vehicles, only 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). Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2487 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2488 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 Exhaust System for the exhaust system-exploded view. 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 PCM with 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair Exhaust Crossover Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2492 Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2493 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2494 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2495 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2496 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2) Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2497 Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2) Removal CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Using a suitable jack, support the exhaust system. 3. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensors electrical connectors. 4. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. ^ Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket. 5. Remove the transmission support crossmember. 6. NOTE: RH side shown, LH similar. Remove the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. ^ Discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. 7. Remove the exhaust Y-pipe dual catalytic converter. Installation 1. NOTE: RH side shown, LH similar. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. NOTE: Do not fully torque the exhaust Y-pipe dual catalytic converter-to-exhaust manifold joint. Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all nuts to stiffen the joint enough to maintain position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2498 ^ Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint. 2. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts. Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts. ^ Tighten to 40 Nm (30 lb-ft). 3. NOTE: RH shown, LH similar. Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. ^ Tighten to 40 Nm (30 lb-ft). 4. Install the transmission support crossmember. 5. Connect the HO2S and catalyst monitor sensors electrical connectors. 6. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Studs ....................................................................................................................... ...................................................... 12 Nm (9 lb-ft). Discard the studs. Exhaust Manifold Nuts ......................................................................................................................... .................................................... 25 Nm (18 lb-ft). Discard the nuts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2502 Exhaust Manifold: Testing and Inspection Exhaust Manifold Cleaning and Inspection 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces. 2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using the 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 in), install a new exhaust manifold. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2505 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Detach the evaporative emission (EVAP) canister purge valve from the bracket and position the valve aside. 3. CAUTION: Do not allow the lower steering column shaft to rotate while it is disconnected from the gear or the clockspring may be damaged. If there is evidence that the lower steering column shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Remove the intermediate steering shaft pinch bolt and disconnect the intermediate steering shaft from the lower steering column shaft. 4. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds. 5. Remove the nuts and position the battery cable bracket aside. 6. Remove the bolts and the LH exhaust manifold heat shield. 7. Remove and discard the pushpin. 8. Remove the 8 nuts, the LH exhaust manifold and the gaskets. ^ Deflect the inner fender splash shield and remove the manifold between the splash shield and the frame rail. ^ Discard the nuts and the gaskets. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2506 9. Remove and discard the 8 LH exhaust manifold studs. Installation 1. Inspect the LH exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new LH exhaust manifold studs. ^ Tighten to 12 Nm (9 lb-ft). 3. Position the new gaskets, the LH exhaust manifold and install new nuts finger-tight. ^ Deflect the inner fender splash shield and install the exhaust manifold between the splash shield and the frame rail. 4. Tighten the exhaust manifold nuts in the sequence shown. ^ Tighten to 25 Nm (18 lb-ft). 5. Position the inner fender splash shield and install a new pushpin. 6. Install the heat shield and the bolts. ^ Tighten to 10 Nm (89 lb-in). 7. Position the battery cable bracket and install the nuts. ^ Tighten to 10 Nm (89 lb-in). 8. Connect the dual converter Y-pipe to the exhaust manifolds and install the 4 nuts. ^ Tighten to 40 Nm (30 lb-ft). 9. Connect the intermediate steering shaft to the lower steering column shaft and install the pinch bolt. ^ Tighten to 48 Nm (35 lb-ft). 10. Attach the EVAP canister purge valve to the bracket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2507 Exhaust Manifold: Service and Repair Exhaust Manifold - RH Exhaust Manifold - RH Removal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2508 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds. 3. Remove the bolts and the RH exhaust manifold heat shield. 4. Remove the pushpins and the RH splash shield. 5. Remove the 8 nuts, the RH exhaust manifold and the gaskets. ^ Discard the nuts and the gaskets. 6. Remove and discard the 8 RH exhaust manifold studs. Installation 1. Inspect the exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new RH exhaust manifold studs. ^ Tighten to 12 Nm (9 lb-ft). 3. Position the new gaskets, the RH exhaust manifold and install new nuts finger-tight. 4. Tighten the nuts in the sequence shown. ^ Tighten to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2509 5. Position the RH splash shield and install the pushpins. 6. Position the heat shield and install the bolts. ^ Tighten to 10 Nm (89 lb-in). 7. Connect the dual converter Y-pipe to the exhaust manifolds and install the nuts. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair Tailpipe Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2513 Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2514 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2515 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2516 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2517 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2) Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2518 Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2) Removal CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Loosen the muffler assembly-to-tailpipe Torca(R) clamp. 3. Disconnect the rubber isolator and remove the tailpipe. Installation 1. Position the tailpipe and connect the rubber isolator. 2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust. Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten the Torca(R) clamp. ^ Tighten to 48 Nm (35 lb-ft). 3. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2522 Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2523 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2524 Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2525 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2526 Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2) Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2527 Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2) Removal All vehicles CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Using a suitable jack, support the exhaust system. 4.0L Explorer Sport Trac 3. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces. NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe. Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe. 4.6L Explorer Sport Trac 4. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces. NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe. Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2528 All vehicles 5. Loosen the muffler assembly-to-tailpipe Torca(R) clamp. 6. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. ^ Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket. 7. Disconnect the rubber isolators and remove the muffler assembly. Installation All vehicles 1. Position the muffler assembly and connect the rubber isolators. 2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust. Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten the Torca(R) clamp. ^ Tighten to 48 Nm (35 lb-ft). 4.0L Explorer Sport Trac 3. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe. NOTE: The factory muffler inlet pipe will not have an alignment nub. If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler. 4. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe. NOTE: The factory muffler inlet pipe will not have an alignment nub. If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2529 ^ Tighten to 47 Nm (35 lb-ft). 4.6L Explorer Sport Trac 5. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe. NOTE: The factory muffler inlet pipe will not have an alignment nub. If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler. 6. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe. NOTE: The factory muffler inlet pipe will not have an alignment nub. If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. ^ Tighten to 47 Nm (35 lb-ft). All Vehicles 7. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts. Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts. ^ Tighten to 40 Nm (30 lb-ft). 8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (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 The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 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. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2536 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2537 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2538 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 separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2542 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2543 View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2544 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2547 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2548 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2549 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2550 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2551 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2552 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2553 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2554 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2555 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2556 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2557 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2558 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2559 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2560 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2561 C175B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2562 C175E (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2563 C175E (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2564 C175E (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2565 C175T (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2566 C175T (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2569 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) A/C Tube Brackets Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2570 PCM Removal All vehicles 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2571 - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2575 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2580 C1450 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations Fuel Pump Control Unit: Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2585 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2586 C4033 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2587 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2591 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2595 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2601 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2602 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2606 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2607 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2608 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2609 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2610 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2615 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2616 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2619 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2620 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2621 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2622 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2632 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2633 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2634 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2635 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2636 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2637 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2641 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2642 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2643 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2647 Fuel Level Sensor: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2648 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2649 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2653 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2654 C435 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2655 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2656 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel tank. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2657 3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2661 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2662 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2663 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2664 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2665 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2669 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2670 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 2677 C104 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 2678 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 2679 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2684 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2685 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2686 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2687 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2688 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2689 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2690 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2691 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2694 C142 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2695 C171 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2696 C172 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2697 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. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2700 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2701 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2702 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2703 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2704 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2708 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2709 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2713 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2717 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2718 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2719 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2720 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2721 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2722 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2726 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2729 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2730 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2731 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2732 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2733 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2734 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2735 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2736 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2737 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2738 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2739 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2740 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2741 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2742 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2743 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2744 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2745 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2746 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2747 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2748 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2749 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2750 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2751 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Vehicle Speed Sensor: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2759 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2764 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2765 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2769 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2770 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2771 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2772 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2773 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2777 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2778 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2779 Fuel Pressure Sensor/Switch: 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2780 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2784 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2785 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2786 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2787 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2791 C282 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2792 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, Roadside Emergencies for the location of the IFS switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2793 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2797 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2798 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2799 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2800 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2801 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 2802 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2808 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2809 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2812 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2813 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2814 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2815 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2819 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2820 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2821 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2822 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2823 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2824 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2832 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2833 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 (KOEO).............................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2838 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 4.6L shown, 4.0L similar. Install the special tool in line between the fuel supply tube and fuel rail. 3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2839 6. NOTE: - 4.6L shown, 4.0L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 630 - 850 RPM ................................................................................................ ...................................................................................................... Hot Idle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2847 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2848 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing..............................................................................................................................................10 degrees before top dead center (BTDC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 2862 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2867 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2868 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2869 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2870 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2871 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2872 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2873 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2874 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2875 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2876 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2877 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap (not adjustable)............................................................................................................ ...................................1.02-1.28 mm (0.040-0.050 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2880 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2881 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type (early build - black coil boot)....................................................................................... ....................................................................PZT-14F Spark plug type (late build - brown coil boot).... ....................................................................................................................................................HJFS -24FP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2882 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. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2883 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(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2884 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2885 Spark Plug: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2886 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2890 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 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2891 Compression Pressure Limit Chart (Part 2) If one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2899 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2900 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2904 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2905 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2906 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2907 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2908 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2912 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2913 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2914 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2915 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2916 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Brake Signal: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2920 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2921 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2922 Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2927 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2928 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2931 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2932 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2933 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2934 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2944 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2945 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2946 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2947 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2948 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2949 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 C251 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Electronic Throttle Actuator: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2972 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2973 C1368 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2974 Electronic Throttle Actuator: Description and Operation ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC) Typical In-line TAC Design Typical Parallel TAC Design The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). There are 2 designs for the TAC, parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (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 The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 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. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2978 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2979 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2980 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 separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2984 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2985 View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2986 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 C175B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 C175E (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 C175E (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 C175E (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 C175T (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 C175T (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3011 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) A/C Tube Brackets Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3012 PCM Removal All vehicles 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3013 - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3017 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3018 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3019 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3023 Fuel Level Sensor: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3024 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3025 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View 151-20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3029 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3030 C435 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3031 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3032 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel tank. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3033 3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 14-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 14-3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 14-4 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3058 Information Bus: Description and Operation COMMUNICATIONS NETWORK NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). 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 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3059 Network Topology MS-CAN Network Operation The MS-CAN communicates using bussed messages. The MS-CAN has an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The MS-CAN is a medium speed communication network used for the following modules: SJB - Audio control module (ACM) - Instrument cluster (IC) - Driver seat module (DSM) (if equipped) - Rear entertainment module (RETM) (if equipped) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3060 - Heating ventilation air conditioning (HVAC) module (if equipped) - Parking aid module (PAM) (if equipped) - Satellite digital audio receiver system (SDARS) module (if equipped) - Power running board (PRB) module (if equipped) HS-CAN Network Operation The HS-CAN communicates using bussed messages. The HS-CAN uses an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The HS-CAN is a high speed communication network used for the following modules: PCM - Transmission control module (TCM) (if equipped) - Restraints control module (RCM) - ABS module - Instrument cluster (IC) - Occupant classification system module (OCSM) - 4X4 control module (if equipped) Network Termination The CAN uses a network termination circuit to improve communication reliability. The network termination of the CAN bus takes place inside the termination modules by termination resistors. Termination modules are located at either end of the bus network. As network messages are broadcast in the form of voltage signals, the network voltage signals are stabilized by the termination resistors. Each termination module has a 120 ohm resistor across the positive and negative bus connection in the termination module. With 2 termination modules on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or total resistance is 60 ohms. Network termination improves bus message reliability by: Stabilizing bus voltage - Eliminating electrical interference 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 3 (50A) (no communication with smart junction box [SJB]) - 6 (40A) (no communication with ABS module) - 19 (30A) (no communication with power running board [PRB] module) - 23 (20A) (no communication with 4X4 control module) - 24 (10A) (no communication with PCM) - 26 (20A) (no communication with 4X4 control module) - 27 (20A) (no communication with transmission control module [TCM]) - 33 (30A) (no communication with ABS module) - 39 (15A) (no communication with PCM) - 41 (15A) (no communication with satellite digital audio receiver system [SDARS] module, rear entertainment module [RETM]) - Smart junction box (SJB) fuse(s): 1 (20A) (no communication with driver seat module [DSM]) - 2 (5A) (no communication with SJB) - 3 (20A) (no communication with audio control module [ACM]) - 4 (20A) (no power to scan tool) - 8 (15A) (no communication with instrument cluster [IC]) - 9 (2A) (no communication with TCM, PCM) - 12 (5A) (no communication with ACM) - 17 (10A) (no communication with restraints control module [RCM], occupant classification system module [OCSM]) - 18 (10A) (no communication with ABS module, 4X4 control module, parking aid module [PAM]) - 20 (10A) (no communication with heating ventilation air conditioning [HVAC]) module - 24 (10A) (no communication with IC) - 28 (10A) (no communication with HVAC module) - Data link connector (DLC) - Wiring harness - Wiring, terminals or connectors 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 T, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Test T: 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 6. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module) See: Diagnostic Trouble Code Descriptions/Module Communications Network 7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3063 Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). 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 will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN operates at a 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 following modules are on the MS-CAN: Audio control module (ACM) - Instrument cluster (IC) - Smart junction box (SJB) - Parking aid module (PAM) (if equipped) - Driver seat module (DSM) (if equipped) - Satellite digital audio receiver system (SDARS) module (if equipped) - Power running board (PRB) module (if equipped) - Rear entertainment module (RETM) (if equipped) - Heating ventilation air conditioning (HVAC) module (if equipped) The following fault chart describes the specific MS-CAN failures and their resulting symptom: MS-CAN Communication Fault Chart 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3064 data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The HS-CAN will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The HS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The HS-CAN operates at a 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 following modules are on the HS-CAN: Instrument cluster (IC) - PCM - ABS module - Restraints control module (RCM) - Occupant classification system module (OCSM) - Transmission control module (TCM) (if equipped) - 4X4 control module (if equipped) The following fault chart describes the specific HS-CAN failures and their resulting symptom: HS-CAN Communication Fault Chart The following chart describes the specific CAN messages broadcast by each module, and the module(s) that receive the message: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3065 CAN Module Communication Message Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3066 CAN Module Communication Message Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3067 CAN Module Communication Message Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3068 CAN Module Communication Message Chart (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3069 CAN Module Communication Message Chart (Part 5) 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 given list are present. See: Programming and Relearning Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). 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 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3070 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. See: Programming and Relearning To carry out PMI, refer to Programmable Module Installation. See: Programming and Relearning Module Reprogramming Module reprogramming (also referred to as "flashing" ) is a scan tool process which updates the strategy/calibration in a module. 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. 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. The following chart lists body/chassis module As-Built data addresses: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3071 Body/Chassis Module Addresses for As-Built Entry The following chart describes specific module programming information: Module Configuration and Parameter Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3072 Module Configuration and Parameter Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3073 Information Bus: Diagnostic Trouble Code Descriptions U0073-U0155 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3074 U0159-U1900 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3075 U1900-U2023 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3076 U2471-U2511 B2477-B2900 / P0602-P1639 / U0300 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3077 U2050-U2051 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3078 Information Bus: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3079 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3080 Symptom Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3081 Information Bus: Pinpoint Tests Test A: The PCM Does Not Respond To The Scan Tool PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL 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 with the transmission control module (TCM) (if equipped), the ABS module, the restraints control module (RCM), the 4X4 control module (if equipped), the occupant classification system module (OCSM) and the instrument cluster (IC). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - PCM A1-A2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3082 A2-A3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3083 A3-A4 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 Normal Operation The 6R60 transmission utilizes a transmission control module (TCM) to control transmission functions. 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 with the PCM, the ABS module, the restraints control module (RCM), the 4X4 control module (if equipped), the occupant classification system module (OCSM) and the instrument cluster (IC). Voltage for the TCM is provided by circuits SBB27 (BU/RD) and CE517 (BU/GN). Circuit GD113 (BK/YE) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TCM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3084 B1-B3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3085 B3-B4 Test C: The ABS Module Does Not Respond To The Scan Tool PINPOINT TEST C: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL 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 with the PCM, the transmission control module (TCM) (if equipped), the restraints control module (RCM), the 4X4 control module (if equipped), the occupant classification system module (OCSM) and the instrument cluster (IC). Voltage for the ABS module is provided by circuits CBP18 (GY/OG), SBB06 (BN/RD) and SBB33 (RD). Ground is provided by circuit GD120 (BK/GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ABS module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3086 C1-C3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3087 C3-C4 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 Normal Operation The restraints control module (RCM) communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the RCM. The RCM shares the HS-CAN with the PCM, the transmission control module (TCM) (if equipped), the ABS module, the 4X4 control module (if equipped), the occupant classification system module (OCSM) and the instrument cluster (IC). Voltage for the RCM is provided by circuit CBP17 (BN/GN), and the RCM is case grounded. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RCM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3088 D1-D3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3089 D4-D5 Test E: The 4X4 Control Module Does Not Respond To The Scan Tool PINPOINT TEST E: THE 4X4 CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The 4X4 control module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the 4X4 control module. The 4X4 control module shares the HS-CAN with PCM, the transmission control module (TCM) (if equipped), the ABS module, the restraints control module (RCM), the occupant classification system module (OCSM) and the instrument cluster (IC). Voltage is supplied by circuits CBP18 (GY/OG), SBB23 (RD/WH) and SBB26 (RD/BK). Ground is supplied by circuits GD138 (BK/WH) and GD145 (BK/BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - 4X4 control module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3090 E1-E2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3091 E3-E4 Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool PINPOINT TEST F: THE OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The occupant classification system module (OCSM) 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 OCSM. The OCSM shares the HS-CAN with the PCM, the transmission control module (TCM) (if equipped), the ABS module, the restraints control module (RCM), the 4X4 control module (if equipped) and the instrument cluster (IC). Voltage to the OCSM is supplied by circuit CBP17 (BN/GN). Ground is supplied by circuit GD145 (BK/BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - OCSM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3092 F1-F2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3093 F2-F3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3094 F4 Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool PINPOINT TEST G: THE INSTRUMENT CLUSTER (IC) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The instrument cluster (IC) communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN connection to the IC and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN connection to the IC. The IC shares the HS-CAN with the PCM, the transmission control module (TCM) (if equipped), the ABS module, the restraints control module (RCM), the 4X4 control module (if equipped) and the occupant classification system module (OCSM). The IC shares the MS-CAN with the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the driver seat module (DSM) (if equipped), the parking aid module (PAM) (if equipped), the PRB module (if equipped) and the rear entertainment module (RETM) (if equipped). Voltage for the IC is provided by circuits CDC34 (WH/OG) and SBP24 (VT/RD). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - IC Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3095 G1-G3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3096 G3-G4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3097 G5 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 Normal Operation The smart junction box (SJB) communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SJB. The SJB shares the MS-CAN with the IC, the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the driver seat module (DSM) (if equipped), the parking aid module (PAM) (if equipped), the power running board (PRB) module (if equipped), and the rear entertainment module (RETM) (if equipped). Voltage for the SJB is provided by circuit SBB03 (BU/RD). Circuit GD108 (BK/VT) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SJB H1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3098 H1-H3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3099 H4-H5 Test I: The Heating Ventilation Air Conditioning (HVAC) Module Does Not Respond To The Scan Tool PINPOINT TEST I: THE HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The heating ventilation air conditioning (HVAC) module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the HVAC module. The HVAC module shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the rear entertainment module (RETM) (if equipped), the driver seat module (DSM) (if equipped), the power running board (PRB) module (if equipped) and the parking aid module (PAM) (if equipped). Voltage for the HVAC module is provided by circuits CBP20 (YE/VT) and SBP28 (GN/RD). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3100 - HVAC module I1-I2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3101 I2-I3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3102 I4 Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool PINPOINT TEST J: THE AUDIO CONTROL MODULE (ACM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the audio control module (ACM). The ACM shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), the rear entertainment module (RETM), the driver seat module (DSM) (if equipped), the power running board (PRB) module (if equipped) and the parking aid module (PAM) (if equipped). Voltage for the ACM is provided by circuits CBP12 (GN/WH) and SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ACM J1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3103 J1-J3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3104 J3-J4 Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool PINPOINT TEST K: THE SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The satellite digital audio receiver system (SDARS) module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SDARS module. The SDARS module shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module (RETM) (if equipped), the driver seat module (DSM) (if equipped), the power running board (PRB) module (if equipped), and the parking aid module (PAM) (if equipped). Voltage for the SDARS module is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SDARS module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3105 K1-K2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3106 K3-K4 Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool PINPOINT TEST L: THE REAR ENTERTAINMENT MODULE (RETM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The rear entertainment module (RETM) communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the RETM. The RETM is only on vehicles equipped with rear seat entertainment. The RETM shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the driver seat module (DSM) (if equipped), the RETM (if equipped), the power running board (PRB) module (if equipped), and the parking aid module (PAM) (if equipped). Voltage for the RETM is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RETM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3107 L1-L2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3108 L2-L3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3109 L4 Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool PINPOINT TEST M: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The driver seat module (DSM) communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the DSM. The DSM shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module (RETM) (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), the power running board (PRB) module (if equipped) and the parking aid module (PAM) (if equipped). Voltage for the DSM is provided by circuit SBP01 (RD). Circuit GD143 (BK/OG) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DSM M1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3110 M1-M3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3111 M3-M4 Test N: The Power Running Board Module Does Not Respond To The Scan Tool PINPOINT TEST N: THE POWER RUNNING BOARD MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The power running board (PRB) module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the PRB module. The PRB module shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module (RETM) (if equipped), the driver seat module (DSM) (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), and the parking aid module (PAM) (if equipped). Voltage for the PRB module is provided by circuit SBB19 (BU/RD). Circuit GD151 (BK/GN) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PRB module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3112 N1-N2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3113 N3-N4 Test O: The Parking Aid Module Does Not Respond To The Scan Tool PINPOINT TEST O: THE PARKING AID MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The parking aid module (PAM) communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the PAM. The PAM shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module (RETM) (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), and the power running board (PRB) module (if equipped). Voltage for the PAM is provided by circuit CBP18 (GY/OG). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PAM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3114 O1-O3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3115 O3-O4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3116 O5-O6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3117 O7-O8 Test P: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING Normal Operation The medium speed controller area network (MS-CAN) uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. The smart junction box (SJB), the instrument cluster (IC), the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the rear entertainment module (RETM) (if equipped), the power running board (PRB) module (if equipped), the parking aid module (PAM) (if equipped), and the driver seat module (DSM) all communicate with the scan tool using the MS-CAN. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3118 - IC - ACM - HVAC module (if equipped) - RETM (if equipped) - DSM (if equipped) - SDARS module (if equipped) - PRB module (if equipped) - PAM (if equipped) P1-P2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3119 P2-P4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3120 P5-P7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3121 P7-P8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3122 P9-P12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3123 P12-P16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3124 P16-P20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3125 P20-P23 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3126 P23-P25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3127 P25-P29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3128 P29-P33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3129 P33-P36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3130 P37-P40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3131 P41-P44 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3132 P45-P46 Test Q: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Responding Dur PINPOINT TEST Q: INTERMITTENT NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST Normal Operation An open circuit VDB06 (GY/OG) (MS-CAN +) or VDB07 (VT/OG) (MS-CAN -) may cause intermittent or unreliable communication to all modules on the high speed controller area network (HS-CAN). The HS-CAN is used for communication between the following modules: - Audio control module (ACM) - Rear entertainment module (RETM) - Driver seat module (DSM) - Heating ventilation air conditioning (HVAC) module - Instrument cluster (IC) - Parking aid module (PAM) - Power running board (PRB) module - Satellite digital audio receiver system (SDARS) module - Smart junction box (SJB) In the event that one of the 2 network circuits (MS-CAN + or MS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3133 Q1 Q1-Q2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3134 Q3-Q6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3135 Q7-Q13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3136 Q14-Q16 Test R: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST R: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING Normal Operation The high speed controller area network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). The PCM, the transmission control module (TCM), the ABS module, the restraints control module (RCM), the 4X4 control module (if equipped), the occupant classification system module (OCSM) and the instrument cluster (IC) all communicate with the scan tool using the HS-CAN. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - PCM - RCM - ABS module - IC - TCM (if equipped) - 4X4 control module (if equipped) - OCSM R1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3137 R1-R2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3138 R3-R4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3139 R5-R6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3140 R7-R8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3141 R8-R10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3142 R10-R11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3143 R12-R16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3144 R16-R18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3145 R18-R20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3146 R20-R23 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3147 R23-R26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3148 R26-R28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3149 R28-R30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3150 R31-R34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3151 R35 Test S: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Responding Durin PINPOINT TEST S: INTERMITTENT NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST Normal Operation An open circuit VDB04 (WH/BU) (HS-CAN +) or VDB05 (WH) (HS-CAN -) may cause intermittent or unreliable communication to all modules on the HS-CAN. The HS-CAN is used for communication between the following modules: ABS module - Instrument cluster (IC) - Occupant classification system module (OCSM) - PCM - Restraints control module (RCM) - Transmission control module (TCM) (6R60 transmission only) - 4X4 control module (if equipped) In the event that one of the 2 network circuits (HS-CAN + or HS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors S1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3152 S1-S2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3153 S3-S5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3154 S6-S11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3155 S12 Test T: No Power To The Scan Tool PINPOINT TEST T: NO POWER TO THE SCAN TOOL 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 SBP04 (GN/RD). Ground is provided by circuits GD108 (BK/VT) and GD138 (BK/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Scan tool T1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3156 T2-T3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3157 Information Bus: Programming and Relearning Programmable Module Installation (PMI) PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Accessory Protocol Interface Module (APIM) Programming Accessory Protocol Interface Module (APIM) Programming Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3158 Accessory Protocol Interface Module (APIM) Programming Using the Integrated Diagnostic System (IDS) NOTE: If a new Accessory Protocol Interface Module (APIM) is being installed, install the new APIM before carrying out the following procedure. 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. NOTE: Do not disconnect the Vehicle Communication Module (VCM) or USB cables during APIM programming. Select the desired software level from the list of available software for programming then select the "Program APIM" button to begin the APIM programming process. Enter the APIM As-Built data if prompted. - When the VIP is programmed, the CIP will be programmed automatically. 9. The Sync/APIM application downloads the software into the APIM and displays "Programming has been completed successfully". 10. Test the audio system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3159 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network > Page 3162 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3166 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3167 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3171 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3181 C104 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3182 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3183 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3188 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3189 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3190 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3191 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3192 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3193 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3194 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3195 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3198 C142 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3199 C171 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3200 C172 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3201 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. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3204 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3205 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3206 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3207 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3208 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3212 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3213 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3217 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (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 The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 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. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3222 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3223 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3224 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 separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3228 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3229 View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3230 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3233 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3234 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3235 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3236 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3237 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3238 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3239 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3240 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3241 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3242 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3243 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3244 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3245 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3246 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3247 C175B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3248 C175E (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3249 C175E (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3250 C175E (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3251 C175T (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3252 C175T (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3255 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) A/C Tube Brackets Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3256 PCM Removal All vehicles 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3257 - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3261 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3266 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3267 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3271 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3272 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3273 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3274 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3275 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3280 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3281 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3284 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3285 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3286 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3287 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams C1064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3297 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3298 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3299 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3300 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3301 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3302 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3306 C107 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3307 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3308 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor. - To install, tighten to 26 Nm 19 lb-ft). 5. To install, reverse the removal procedure. - Do not reuse the CHT sensor. Install a new sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3312 Fuel Level Sensor: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3313 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3314 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3318 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3319 C435 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3320 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3321 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel tank. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3322 3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3326 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3327 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3328 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3329 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3330 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3334 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3335 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3342 C104 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3343 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3344 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 View 151-10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3349 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3350 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3351 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3352 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3353 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3354 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3355 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3356 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3359 C142 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3360 C171 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3361 C172 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3362 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. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3365 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3366 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3367 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3368 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3369 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3373 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3374 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3378 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3382 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3383 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3384 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3385 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3386 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3387 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3391 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3394 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3395 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3396 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3397 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3398 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3399 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3400 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3401 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3402 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3403 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3404 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3405 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3406 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3407 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3408 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3409 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3410 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3411 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3412 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3413 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3414 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3415 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3416 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3423 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3424 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3425 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3426 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3427 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3428 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3432 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3449 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3450 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3451 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3452 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3453 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3454 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3455 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3456 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3457 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3462 C1452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3463 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 (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3464 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Catalyst Efficiency Monitor For most vehicles, only 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). Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3485 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3486 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 Exhaust System for the exhaust system-exploded view. 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 PCM with 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams C1029 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3491 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3492 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER PURGE VALVE Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector. 4. Disconnect the 2 vapor tube quick connect couplings from the EVAP canister purge valve. 5. Detach the EVAP canister purge valve from the bracket and remove. 6. To install, reverse the removal procedure. 7. Leak test the EVAP system. See: Testing and Inspection 8. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor hose from the dust separator. 5. Remove the bolt and the dust separator. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 7. Leak test the evaporative emission (EVAP) system. See: Testing and Inspection 8. Carry out the evaporative emission repair drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Diagrams C450 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the fuel tank. 4. Detach the evaporative emission (EVAP) canister from the fuel tank to gain access to the quick connect coupling. 5. Disconnect the fuel tank pressure (FTP) sensor and tube assembly quick connect coupling from the EVAP canister. 6. Disconnect the vapor hose from the EVAP canister. 7. Remove the EVAP canister. 8. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 9. Leak test the EVAP system. See: Testing and Inspection 10. Carry out the evaporative emission repair verification drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service and Repair Liquid Vapor Separator: Service and Repair FUEL VAPOR VENT VALVE Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor vent valve electrical connector. 4. Disconnect the fuel vapor hoses from the fuel vapor vent valve and remove the fuel vapor vent valve. 5. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 6. Leak test the evaporative emission (EVAP) system. See: Testing and Inspection 7. Carry out the evaporative emission repair drive cycle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations > Page 3512 C1450 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation EGR Valve: Description and Operation 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). Exhaust Gas Recirculation (EGR) System Module (ESM) ESM Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3522 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3526 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams C190 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 3535 C1450 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3540 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 (KOEO).............................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3545 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 4.6L shown, 4.0L similar. Install the special tool in line between the fuel supply tube and fuel rail. 3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3546 6. NOTE: - 4.6L shown, 4.0L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 630 - 850 RPM ................................................................................................ ...................................................................................................... Hot Idle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed ACCELERATOR PEDAL - FIXED Removal and Installation 1. Disconnect the accelerator pedal electrical connector. 2. Remove the nuts and the accelerator pedal assembly. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3558 Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable ACCELERATOR PEDAL - ADJUSTABLE Removal and Installation 1. The adjustable accelerator pedal and adjustable brake pedal must be serviced as a unit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3562 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3563 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3568 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3569 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3573 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3574 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3575 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3576 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3577 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3589 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ..................................................................... Refer to Pinpoint Test HC12 and HC13 at Computers and Control Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 C181 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3592 C182 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3593 C183 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3594 C184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3595 Fuel Injector: Diagrams C181 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3596 C182 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3597 C183 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3598 C184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3599 C185 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3600 C186 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3601 C187 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3602 C188 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3603 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3604 Fuel Injector: Service and Repair FUEL RAIL Part 1 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3605 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. NOTE: During the repair or installation of new fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation. 1. Release the fuel system pressure. 2. Disconnect the fuel supply tube spring lock coupling. 3. Detach the 2 PCV coolant hose retainers from the fuel rail stud bolts and position the hose aside. 4. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum hose. 5. Disconnect the 8 fuel injector electrical connectors. 6. Remove the fuel rail stud bolts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the fuel rail and fuel injectors as an assembly from the intake manifold. 8. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is reused, the 2 sides of the clip should be squeezed back into shape by placing it between index finger and thumb. Remove the retaining clips and fuel injectors from the fuel rail. 9. CAUTION: - O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. - Do not reuse O-ring seals. The removal and installation process may damage the used O-ring seals, and cause the fuel system to leak. Remove and discard the fuel injector O-ring seals. 10. To install, reverse the removal procedure. - Lubricate the new upper and lower fuel injector O-ring seals with clean engine oil prior to installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 - Type I WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the safety clip from the fuel tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3610 4. Install the special tool and press it into the spring lock coupling. 5. Separate the spring lock coupling. Connect - Type I 1. Inspect and clean both spring lock coupling ends. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Lubricate the spring lock coupling with clean engine oil. Align the fuel tube spring lock coupling and push together until a click is heard. 3. Pull on the spring lock coupling to make sure it is fully seated. Install the fuel tube safety clip on the male end. Disconnect - Type II Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3611 WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the fuel tube safety clip. 4. Install the special tool. 5. Close and push the special tool into the open side of the cage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3612 6. Separate the spring lock coupling. Connect - Type II 1. Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if necessary. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to O-ring seals. Fit the male end 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 tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3613 4. Install the fuel tube safety clip Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3614 Fuel Line Coupler: Service and Repair Quick Connect Coupling QUICK CONNECT COUPLING Disconnect - Type I WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Unclip the locking tab. 4. Depress the tabs and press the clip downward. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3615 5. Separate the quick connect coupling. Connect - Type I 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Lubricate the quick connect coupling with clean engine oil. Connect the quick connect coupling. 3. Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated correctly. 4. Clip the locking tab in place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3616 Disconnect - Type II WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 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 II 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3617 - 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. - Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Disconnect - Type III WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. Release the locking tab on the quick connect coupling. 2. Separate the quick connect coupling from the fitting. Connect - Type III 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3618 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to O-ring seals. Release the locking tab and install the quick connect coupling onto the fitting. 3. Position the locking tab into the latched position. Disconnect - Type IV WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3619 3. Compress the clip legs and push the clip into the quick connect coupling. 4. Separate the quick connect coupling from the tube. Connect - Type IV 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to O-ring seals. Fully insert the male tube end in the quick connect coupling and push the clip downward to lock the fuel tubes together. 3. Pull on the connection to make sure it is fully engaged. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3623 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3624 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3625 Fuel Pressure Sensor/Switch: 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3626 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 (KOEO).............................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3634 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 4.6L shown, 4.0L similar. Install the special tool in line between the fuel supply tube and fuel rail. 3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3635 6. NOTE: - 4.6L shown, 4.0L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations Fuel Pump Control Unit: Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3639 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3640 C4033 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3641 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3645 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair FUEL RAIL Part 1 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 3649 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. NOTE: During the repair or installation of new fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation. 1. Release the fuel system pressure. 2. Disconnect the fuel supply tube spring lock coupling. 3. Detach the 2 PCV coolant hose retainers from the fuel rail stud bolts and position the hose aside. 4. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum hose. 5. Disconnect the 8 fuel injector electrical connectors. 6. Remove the fuel rail stud bolts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the fuel rail and fuel injectors as an assembly from the intake manifold. 8. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is reused, the 2 sides of the clip should be squeezed back into shape by placing it between index finger and thumb. Remove the retaining clips and fuel injectors from the fuel rail. 9. CAUTION: - O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. - Do not reuse O-ring seals. The removal and installation process may damage the used O-ring seals, and cause the fuel system to leak. Remove and discard the fuel injector O-ring seals. 10. To install, reverse the removal procedure. - Lubricate the new upper and lower fuel injector O-ring seals with clean engine oil prior to installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3653 Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3654 Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3655 Explorer/Mountaineer (Part 2) Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the battery ground cable. 4. Disconnect the spring lock coupling at the engine and the vapor tube quick connect coupling at the purge valve. 5. Disconnect the quick connect coupling at the fuel filter and the vapor tube quick connect coupling at the fuel tank. 6. Remove the transmission. 7. Remove the fuel lines from the vehicle. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3660 Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3661 Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3662 Explorer/Mountaineer (Part 2) Exploded View Removal and Installation All vehicles WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. - Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. Drain the fuel tank. 2. NOTE: The fuel tank filler pipe hose between the fuel tank filler pipe and the fuel tank is serviceable separately. The fuel tank filler pipe does not have to be removed from the vehicle to service the fuel tank filler pipe hose. If necessary, loosen the fuel tank filler pipe hose clamp at the fuel tank and disconnect the hose and remove from the vehicle. To install, tighten to 3 Nm (27 lb-in). 3. If equipped, open the fuel tank filler cap. 4. Remove the 3 bolts. - To install, tighten to 1 Nm (9 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3663 Explorer/Mountaineer 5. NOTE: Body panel and fuel door removed for clarity. Depress the 2 tabs on the fresh air vent tube in the fuel filler door pocket and disconnect the fresh air vent tube from the inner fenderwell. Explorer/Mountaineer late build vehicles 6. Remove the fuel tank filler pipe upper retainer. All vehicles 7. Disconnect the fuel filler pipe vapor tube-to-fuel pressure sensor and vapor tube assembly quick connect coupling. 8. Disconnect the rear axle vent hose. 9. Disconnect the dust separator hose. 10. Remove the 2 bolts and the fuel tank filler pipe assembly. - To install, tighten to 15 Nm (11 lb-ft). 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams C434A C434B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3667 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3668 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3669 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3670 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3671 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair FUEL TANK SUPPORT STRAPS Explorer Sport Trac (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3675 Explorer Sport Trac (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3676 Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3677 Explorer/Mountaineer (Part 2) Exploded View Removal and Installation All vehicles WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the 4 bolts, the nut and the fuel tank skid plate. - To install, tighten to 40 Nm (30 lb-ft). Explorer/Mountaineer 3. Remove the driveshaft. All vehicles 4. Using a suitable jack, support the fuel tank. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3678 5. Remove the bolt and the fuel tank rear support strap. - To install, tighten to 48 Nm (35 lb-ft). 6. Remove the nut and the fuel tank front support strap. - To install, tighten to 48 Nm (35 lb-ft). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Page 3682 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3686 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3687 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3688 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3689 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3696 C282 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3697 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, Roadside Emergencies for the location of the IFS switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3698 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Coolant Expansion Tank Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 3702 Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 3703 Intake Air System Components - 4.6L (3V) Exploded View Removal and Installation Vehicles equipped with a 4.0L SOHC engine 1. Detach the wiring harness retainer from the cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Disconnect the brake booster vacuum hose from the air cleaner outlet pipe. All vehicles 3. Disconnect the crankcase breather hose from the air cleaner outlet pipe. 4. Loosen the clamps and remove the air cleaner outlet pipe. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3707 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations Fuel Pump Control Unit: Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3712 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3713 C4033 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3714 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3718 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3722 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3727 C2040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3728 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 amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 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. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 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. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3732 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3733 C1454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3734 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3735 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3736 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 bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3740 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3741 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3742 Fuel Pressure Sensor/Switch: 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3743 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3747 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3748 C173 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3749 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3750 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Lubricate the O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3754 C282 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3755 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, Roadside Emergencies for the location of the IFS switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3756 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3760 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3761 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3762 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3763 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3764 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3765 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY Removal and Installation CAUTION: The throttle body (TB) 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 TB or the TB may be damaged. 1. Remove the air cleaner outlet pipe. 2. Disconnect the electronic throttle control electrical connector. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. Remove the bolts, the throttle body (TB) and the TB gasket. Discard the gasket. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3772 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3773 C189 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3774 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3775 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Heated PCV Fitting Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3776 Throttle Position (TP) Sensor Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove the bolts and position the heated PCV fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the throttle position (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 All vehicles 1. CAUTION: - Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be installed. Failure to follow this instruction may result in poor engine performance. - Do not use a high-speed driver to install the new screws or damage to the throttle position (TP) sensor may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3777 - Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Description and Operation Variable Induction Control Actuator: Description and Operation 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Description and Operation > Page 3782 Variable Induction Control Actuator: Service and Repair CHARGE MOTION CONTROL VALVE (CMCV) Removal 1. Remove the intake manifold. 2. NOTE: Do not disconnect the linkages at the intake manifold unless a new intake manifold is being installed. Remove and discard the 2 E-clips and disconnect the charge motion control valve (CMCV) linkages from the CMCV. 3. NOTE: Bent shaft or damaged components will require a new intake manifold. Rotate each CMCV shaft by hand to verify that they do not stick or bind. 4. Remove the 3 bolts and the CMCV. Installation 1. Position the CMCV and loosely install the 3 bolts. - Do not tighten the bolts at this time. 2. Rotate each CMCV shaft so that the plates are in the closed position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Description and Operation > Page 3783 3. Install the RH and LH CMCV plate alignment locks. 4. Connect the RH and LH CMCV linkages to the CMCV and install 2 new E-clips. 5. Verify that the CMCV plate alignment locks are still correctly located and tighten the 3 CMCV bolts. - Tighten to 10 Nm (89 lb-in). 6. Remove the RH and LH alignment locks. 7. Install the intake manifold. 8. Carry out the key ON engine OFF (KOEO) self-test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing..............................................................................................................................................10 degrees before top dead center (BTDC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3795 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3796 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3799 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3800 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3801 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3802 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3806 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3807 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3808 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3809 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3810 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3811 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Page 3815 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 C111 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3821 C112 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3822 C113 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3823 C114 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3824 Ignition Coil: Diagrams C111 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3825 C112 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3826 C113 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3827 C114 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3828 C115 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3829 C116 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3830 C117 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3831 C118 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3832 C1196 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3833 C174 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3834 C194 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3835 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3836 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3837 Ignition Coil: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3838 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3842 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3843 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3849 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3850 View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3853 C1366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3854 C1367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3855 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3856 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation RH side 1. Remove the air cleaner (ACL) outlet pipe. Both sides 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3860 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3861 Crankshaft Position Sensor: Diagrams C101 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3862 C1120 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3863 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3864 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3865 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the stud bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3873 C108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3874 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3879 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3880 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3881 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3882 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3883 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3884 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3885 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3886 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3887 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3888 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3889 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap (not adjustable)............................................................................................................ ...................................1.02-1.28 mm (0.040-0.050 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications > Page 3892 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3893 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type (early build - black coil boot)....................................................................................... ....................................................................PZT-14F Spark plug type (late build - brown coil boot).... ....................................................................................................................................................HJFS -24FP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3894 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. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3895 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(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3896 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3897 Spark Plug: Service and Repair Ignition Components RH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3898 Ignition Components LH Side Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 3906 Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3909 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3910 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3911 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3912 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3913 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3914 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3915 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3916 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3917 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3918 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3919 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3920 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3921 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3922 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3923 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3924 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3925 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3926 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3927 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3928 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3929 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3930 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. 2. Disconnect the brake shift interlock actuator electrical connector. 3. Remove the screw and the brake shift interlock actuator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3934 Installation 1. Install the brake shift interlock actuator. 2. Connect the brake shift interlock actuator electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 3939 Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3942 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3943 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3944 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3945 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3946 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3947 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3948 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3949 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3950 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3951 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3952 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3953 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3954 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3955 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3956 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3957 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3958 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3959 Shift Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3960 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3961 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3962 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3963 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3969 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3970 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3971 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3972 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3973 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3974 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3975 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3976 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3977 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3978 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3979 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3980 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 3981 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3982 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3983 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3984 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3985 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3986 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair Transfer Case Actuator: Service and Repair Transfer Case Shift Motor Removal and Installation 1. With the ignition ON, press the 4X4 HIGH button on the mode select switch (MSS). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the 3 heat shield bolts and the heat shield. ^ To install, tighten to 16 Nm (12 lb-ft). 4. Disconnect the transfer case shift motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 3991 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. ^ To install, tighten to 10 Nm (89 lb-inch). 7. To install, reverse the removal procedure. ^ Apply a coat of multi-purpose grease to the transfer case shift motor bolts. ^ Apply a thin coat of silicone sealant to the shift motor sealing surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 4002 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4007 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module > Page 4010 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module > Page 4011 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Page 4012 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4019 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4020 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4021 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4022 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4023 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4024 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4025 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4026 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4027 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4028 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4029 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4030 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4031 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4032 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4037 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4038 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4039 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4040 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4041 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4042 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4043 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4044 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4045 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4046 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4047 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4048 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4049 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4054 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4055 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4056 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4057 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4058 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4059 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4060 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4061 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4062 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4063 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4064 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4065 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4066 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4072 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4073 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4074 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4075 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4076 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4077 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4078 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4079 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4080 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4081 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4082 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4083 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4084 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 4087 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4088 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4092 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4095 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4096 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4097 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4098 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4099 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4100 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4101 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4102 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4103 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4104 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4105 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4106 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4107 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4108 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4109 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4110 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4111 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4112 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4113 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4114 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4115 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4116 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4117 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4122 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4123 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4124 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4127 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4128 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4129 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4130 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4131 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4132 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4133 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4134 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4135 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4136 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4137 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4138 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4139 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4140 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4141 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4144 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4145 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4146 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4147 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4148 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4149 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4150 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4151 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4152 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4153 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4154 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4155 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4156 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4157 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4158 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4159 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 4160 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4165 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4166 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4167 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4168 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4169 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4170 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4171 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4172 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4173 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4174 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4175 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4176 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4177 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4182 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4183 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4184 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0456 Stored In ECM TSB 09-1-2 01/26/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0456 - BUILT ON OR BEFORE 4/14/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-16-10 to add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes. ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control module (TCM) if necessary. SERVICE PROCEDURE Use the correct procedure for the vehicle application you are working on. For all 4.0L engines follow Procedure A and for all 4.6L engines follow Procedure B. Procedure A (4.0L Engine) 1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Procedure B (4.6L Engine) NOTE VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS 1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle. 2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 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. 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: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4193 (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 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. (3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). 4. 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) five (5) times in the dealership parking lot or similar setting. d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. h. Repeat Steps (e-f) a total of three (3) times. NOTE AUTHORIZATION DECAL NOT REQUIRED. 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 090102A 2006-2008 Explorer, 0.3 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do Not Use With 12650D) 090102B 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4194 DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump PROM - Programmable Read Only Memory: Customer Interest A/T, Engine Controls - Low Speed Driveline Bump TSB 08-24-4 12/08/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-4-16 to update the Service Procedure. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR / REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent and ID the vehicle. 2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. NOTE AUTHORIZATION DECAL NOT REQUIRED. a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after 12/3/2007) part number after reprogramming is complete. Select the following from the IDS tool, Toolbox, 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4199 FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from 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) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate gently to 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 ten (10) seconds. g. Repeat Steps (d-f) a total of three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING MAY BE 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 082404A 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4200 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T PROM - Programmable Read Only Memory: Customer Interest A/T - PCM/TCM Update Required When Replacing A/T TSB 08-13-6 07/07/08 6R60-6R75 TRANSMISSIONS - REPLACEMENT REQUIREMENTS - JOB 1 ONLY FORD: 2008 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008 Mountaineer ISSUE The 2008 Explorer Sport Trac, Mountaineer, Explorer 4dr vehicles that were built on or before 11/29/2007 and Expedition vehicles that were built on or before 12/3/2007 were built with a unique transmission assembly. Only the later (Job-2) transmission design will be available as a service replacement. The later transmission design has internal changes that are incompatible with previous calibrations. If transmission replacement is required then a coordinated powertrain control module (PCM)/ transmission control module (1CM) reprogramming will be necessary to support these changes of internal hardware. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The transmission serial number is located on the driver side lower left side behind the manual lever: Refer to Workshop Manual (WSM), Section 307-01A. ^ Job-1 8L2Z-7000-C will be replaced by Job-2 8L2Z-7000-E (4x2) 6R60 ^ Job-1 8L2Z-7000-D will be replaced by Job-2 8L2Z-7000-F (4X4) 6R60 ^ Job-1 8L1Z-7000-A will be replaced by Job-2 8LiZ-7000-C (4X2) 6R75 ^ Job-1 8L1Z-7000-B will be replaced by Job-2 8LiZ-7000-D (4X4) 6R75 NOTE VEHICLES THAT HAVE USED THIS PROCEDURE, ANY FUTURE PCM REPLACEMENTS WILL REQUIRE TRANSMISSION SERIAL NUMBER IDENTIFICATION FOR IDS REPROGRAMMING SELECTIONS. Follow Work Shop Manual for Transmission Replacement Procedure. NOTE VEHICLES REFERENCED IN THIS ARTICLE ARE EQUIPPED WITH A PCM AND TCM, AND REQUIRE A COORDINATED FLASH. THIS COORDINATED FLASH PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED FLASH TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS TO ENSURE A PROPER REPAIR. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM/TCM calibration using IDS release 55.11 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. Since the TCM cannot be independently reprogrammed, reprogram the PCM using the "PMI" function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. Verify TCM shows correct part number after reprogramming is complete. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4205 (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 1CM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. 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 the unit to perform adaptive shift strategy learn. a. Accelerate from a stop 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) five (5) times in the dealership parking lot or similar setting. d. Accelerate from a stop 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 10 seconds. g. Repeat steps (e-f) three (3) 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 081306A 2008 Expedition, Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac: Check DTCs, Reprogram PCM/TCM, Includes Time To Clear TCM KAM, Raise Vehicle To Verify Transmission Serial Number And, Perform Road Test (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4206 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-9-5 > May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/Rough Idle After Hot Soak TSB 08-9-5 05/12/08 4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN COMING TO A STOP - BUILT ON OR BEFORE 4/212008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard start / rough running condition after a long hot soak. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080905A 2006-2008 0.3 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel PROM - Programmable Read Only Memory: Customer Interest A/T - Delayed Engagement/Hesitation/Bump on Decel TSB 07-23-2 11/26/07 6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 07-13-8 to update the Service Procedure. ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms: ^ Delayed engagements into Drive from Park Neutral or Reverse. ^ Hesitation upon tip-in after braking to a stop. This fixes the bump while braking to a stop, improves the delayed engagements and reduces the incidence of tip-in hesitation while accelerating from a stop. ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM) and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in order to provide smooth operation. This calibration update will help to improve the condition. The harsh bump while braking to a stop will be eliminated. Several days of driving may be required for the transmission to fully adapt. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher. 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. 3. Clear 1CM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose 1CM. b. Using PDS: (1) Choose all Tests and Calibrations. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4215 (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. 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-c) 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 072302A 2006-2008 Explorer, 0.9 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0456 Stored In ECM TSB 09-1-2 01/26/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0456 - BUILT ON OR BEFORE 4/14/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-16-10 to add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes. ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control module (TCM) if necessary. SERVICE PROCEDURE Use the correct procedure for the vehicle application you are working on. For all 4.0L engines follow Procedure A and for all 4.6L engines follow Procedure B. Procedure A (4.0L Engine) 1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Procedure B (4.6L Engine) NOTE VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS 1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle. 2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 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. 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: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4221 (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 UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. (3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). 4. 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) five (5) times in the dealership parking lot or similar setting. d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. h. Repeat Steps (e-f) a total of three (3) times. NOTE AUTHORIZATION DECAL NOT REQUIRED. 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 090102A 2006-2008 Explorer, 0.3 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do Not Use With 12650D) 090102B 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4222 DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T, Engine Controls Low Speed Driveline Bump TSB 08-24-4 12/08/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-4-16 to update the Service Procedure. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR / REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent and ID the vehicle. 2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. NOTE AUTHORIZATION DECAL NOT REQUIRED. a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after 12/3/2007) part number after reprogramming is complete. Select the following from the IDS tool, Toolbox, 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4227 FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from 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) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate gently to 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 ten (10) seconds. g. Repeat Steps (d-f) a total of three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING MAY BE 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 082404A 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4228 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4233 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4234 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4235 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4236 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4237 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - PCM/TCM Update Required When Replacing A/T TSB 08-13-6 07/07/08 6R60-6R75 TRANSMISSIONS - REPLACEMENT REQUIREMENTS - JOB 1 ONLY FORD: 2008 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008 Mountaineer ISSUE The 2008 Explorer Sport Trac, Mountaineer, Explorer 4dr vehicles that were built on or before 11/29/2007 and Expedition vehicles that were built on or before 12/3/2007 were built with a unique transmission assembly. Only the later (Job-2) transmission design will be available as a service replacement. The later transmission design has internal changes that are incompatible with previous calibrations. If transmission replacement is required then a coordinated powertrain control module (PCM)/ transmission control module (1CM) reprogramming will be necessary to support these changes of internal hardware. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The transmission serial number is located on the driver side lower left side behind the manual lever: Refer to Workshop Manual (WSM), Section 307-01A. ^ Job-1 8L2Z-7000-C will be replaced by Job-2 8L2Z-7000-E (4x2) 6R60 ^ Job-1 8L2Z-7000-D will be replaced by Job-2 8L2Z-7000-F (4X4) 6R60 ^ Job-1 8L1Z-7000-A will be replaced by Job-2 8LiZ-7000-C (4X2) 6R75 ^ Job-1 8L1Z-7000-B will be replaced by Job-2 8LiZ-7000-D (4X4) 6R75 NOTE VEHICLES THAT HAVE USED THIS PROCEDURE, ANY FUTURE PCM REPLACEMENTS WILL REQUIRE TRANSMISSION SERIAL NUMBER IDENTIFICATION FOR IDS REPROGRAMMING SELECTIONS. Follow Work Shop Manual for Transmission Replacement Procedure. NOTE VEHICLES REFERENCED IN THIS ARTICLE ARE EQUIPPED WITH A PCM AND TCM, AND REQUIRE A COORDINATED FLASH. THIS COORDINATED FLASH PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED FLASH TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS TO ENSURE A PROPER REPAIR. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM/TCM calibration using IDS release 55.11 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. Since the TCM cannot be independently reprogrammed, reprogram the PCM using the "PMI" function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. Verify TCM shows correct part number after reprogramming is complete. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4242 (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 1CM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. 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 the unit to perform adaptive shift strategy learn. a. Accelerate from a stop 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) five (5) times in the dealership parking lot or similar setting. d. Accelerate from a stop 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 10 seconds. g. Repeat steps (e-f) three (3) 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 081306A 2008 Expedition, Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac: Check DTCs, Reprogram PCM/TCM, Includes Time To Clear TCM KAM, Raise Vehicle To Verify Transmission Serial Number And, Perform Road Test (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4243 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-9-5 > May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard Start/Rough Idle After Hot Soak TSB 08-9-5 05/12/08 4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN COMING TO A STOP - BUILT ON OR BEFORE 4/212008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard start / rough running condition after a long hot soak. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080905A 2006-2008 0.3 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Delayed Engagement/Hesitation/Bump on Decel TSB 07-23-2 11/26/07 6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 07-13-8 to update the Service Procedure. ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms: ^ Delayed engagements into Drive from Park Neutral or Reverse. ^ Hesitation upon tip-in after braking to a stop. This fixes the bump while braking to a stop, improves the delayed engagements and reduces the incidence of tip-in hesitation while accelerating from a stop. ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM) and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in order to provide smooth operation. This calibration update will help to improve the condition. The harsh bump while braking to a stop will be eliminated. Several days of driving may be required for the transmission to fully adapt. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher. 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. 3. Clear 1CM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose 1CM. b. Using PDS: (1) Choose all Tests and Calibrations. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4252 (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. 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-c) 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 072302A 2006-2008 Explorer, 0.9 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4258 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4259 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4260 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4261 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4262 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S Automatic Transaxle/Transmission Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S Automatic Transaxle/Transmission > Page 4270 Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4273 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4274 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4275 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4276 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4277 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4278 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4279 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4280 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4281 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4282 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4283 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4284 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4285 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4286 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4287 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4288 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4289 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4290 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4291 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4292 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4293 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4294 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. 2. Disconnect the brake shift interlock actuator electrical connector. 3. Remove the screw and the brake shift interlock actuator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Page 4298 Installation 1. Install the brake shift interlock actuator. 2. Connect the brake shift interlock actuator electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4303 Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4306 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4307 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4308 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4309 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4310 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4311 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4312 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4313 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4314 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4315 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4316 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4317 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4318 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4319 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4320 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4321 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4322 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4323 Shift Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4324 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4325 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4326 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4327 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4333 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4334 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4335 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4336 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4337 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4338 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4339 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4340 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4341 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4342 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4343 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4344 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4345 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4346 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4347 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4348 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4349 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4350 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair Transfer Case Actuator: Service and Repair Transfer Case Shift Motor Removal and Installation 1. With the ignition ON, press the 4X4 HIGH button on the mode select switch (MSS). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the 3 heat shield bolts and the heat shield. ^ To install, tighten to 16 Nm (12 lb-ft). 4. Disconnect the transfer case shift motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 4355 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. ^ To install, tighten to 10 Nm (89 lb-inch). 7. To install, reverse the removal procedure. ^ Apply a coat of multi-purpose grease to the transfer case shift motor bolts. ^ Apply a thin coat of silicone sealant to the shift motor sealing surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4362 Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4365 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4366 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4367 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4368 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4369 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4370 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4371 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4372 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4373 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4374 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4375 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4376 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4377 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4378 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4379 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4380 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4381 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4382 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4383 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4384 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4385 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4386 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. 2. Disconnect the brake shift interlock actuator electrical connector. 3. Remove the screw and the brake shift interlock actuator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4390 Installation 1. Install the brake shift interlock actuator. 2. Connect the brake shift interlock actuator electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4395 Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4398 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4399 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4400 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4401 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4402 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4403 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4404 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4405 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4406 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4407 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4408 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4409 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4410 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4411 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4412 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4413 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4414 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4415 Shift Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4416 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4417 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4418 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4419 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4425 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4426 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4427 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4428 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4429 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4430 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4431 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4432 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4433 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4434 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4435 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4436 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4437 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4438 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4439 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4440 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4441 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4442 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart - 5R55S Band: Specifications Band Adjustment and Torque Chart - 5R55S Band Adjustment and Torque Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart - 5R55S > Page 4447 Band: Specifications Band and Clutch Application Chart A - 5R55S Band and Clutch Application Chart A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart - 5R55S > Page 4448 Band: Specifications Band and Clutch Application Chart B - 5R55S Band and Clutch Application Chart B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Band Apply Servo: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4457 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4458 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4459 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4460 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4466 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4467 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4468 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4469 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 4487 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Case: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4496 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4497 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4498 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4499 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4505 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4506 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4507 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4508 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch Application Chart - 6R60 Clutch: Specifications Clutch Application Chart - 6R60 Clutch Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch Application Chart - 6R60 > Page 4513 Clutch: Specifications Clutch Plate Quantity - 6R60 Clutch Plate Quantity Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 4517 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 5R55S .................................................................................................................. ............................................................................. 12.4 quarts (11.7 liters) 6R60 ................................ .............................................................................................................................................................. .... 11.2 quarts (10.6 liters) Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be checked by a qualified technician. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4522 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type 5R55S .................................................................................................................................................. ............................................. MERCON V XT-5-QM 6R60 .................................................................. ............................................................................................................................. MERCON SP XT-6-QSP Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission Fluid - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission Transmission Fluid Level Check Transmission Fluid Level Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4525 Transmission Fluid Fill Reference 1. Using the scan tool, monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27-49° C (80-120° F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. 7. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4526 8. Install the special tool into the pan. 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4527 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission fluid pan. 13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the transmission fluid level in the special tool. If the transmission fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra transmission fluid trapped in the system and direct it into the container. 16. Allow the transmission fluid to drain. Make sure that the fluid temperature is between 27-49° C (80-120° F). When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4528 17. Reinstall the small (center) transmission fluid level indicating plug using a 3/16-inch Allen key. ^ Tighten to 10 Nm (89 lb-inch). 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Transmission Fluid Drain and Refill - Automated Equipment Transmission Fluid Drain and Refill - Automated Equipment Draining CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. CAUTION: Always refer to the instructions supplied with the flush and fill machine or transmission damage can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4529 1. With the vehicle in PARK, position it on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission fluid cooler tube after the transmission fluid cooler on the transmission fluid cooler return tube. This will help remove any foreign material trapped in the transmission fluid coolers. Refill 1. Use only clean transmission fluid. 2. Once the transmission fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the engine running, check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. For additional information, refer to Transmission Fluid Level Check. See: Service and Repair/Procedures/Transmission Fluid Level Check Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4530 Fluid Fill Reference NOTE: Left side of case shown. Fluid Fill Reference Draining 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2. Remove the transmission fluid drain plug (large plug) and allow the fluid to drain. Refill 1. Install the transmission fluid drain plug. ^ Tighten to 26 Nm (19 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4531 2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 3. Install the special tool into the transmission fluid pan. 4. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4532 5. Hang the special tool under the vehicle, upright and close to the transmission. 6. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4533 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the transmission fluid temperature is between 27° C-49° C (80° F-120° F). 10. Inspect the transmission fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the transmission fluid to drain. When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. 13. Reinstall the small (center) transmission fluid level indicating plug. ^ Tighten to 10 Nm (89 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4534 Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines. ^ Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4535 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4536 Fluid - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission Transmission Fluid Level Check Transmission Fluid Level Check CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler, cooler tubes 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 transmission fluid cooling system. 1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK. 2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the transmission fluid level indicator from the transmission fluid fill plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4537 5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. 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 transmission fluid level must be at the upper level of the crosshatch mark. 7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4538 Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4539 Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill plug. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4540 5. 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 transmission fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. CAUTION: The transmission 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 transmission fluid leaking, the transmission fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. ^ Adding 3.3L (3.5 qt) of clean transmission fluid to the transmission is an initial fill enabling you to start the engine. ^ The cold transmission fluid level range shown in the procedure allows the vehicle to be driven. ^ The vehicle should be driven to allow the transmission fluid temperature to reach 85° C-88° C (185° F-190° F) in order to purge the air from the transmission fluid cooling system. ^ Fill the transmission fluid to the full range on the transmission fluid level indicator at the normal operating range 80° C-85° C (175° F-185° F). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean transmission fluid added to the transmission as an initial fill if: ^ the transmission has been overhauled. ^ a new mechatronic assembly has been installed. ^ the transmission fluid pan or transmission fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean transmission fluid to the transmission through the transmission 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). ^ With the engine running, use the scan tool to monitor transmission fluid temperature and engine speed. 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 transmission fluid level indicator from the transmission fluid fill plug. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4541 4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 5. Add clean transmission fluid to the cold level location as shown in the illustration. 1 Transmission fluid cold level. 6. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4542 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 transmission fluid 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. 9. Separate the transmission fluid level indicator from the transmission fluid fill plug. 10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4543 11. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. 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 transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the special tool into the transmission fluid fill hole. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4544 2. Fill the special tool with approximately 0.47L (1 pt) of clean transmission fluid. 3. Hang the special tool under the vehicle, upright and close to the transmission. 4. Connect the special tools. ^ Connect the open end of the hose from the special tool onto the special tool from the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4545 5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission. 6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 7. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4546 Removing Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the special tools to extract any excessive transmission fluid. 2. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175° F-185° F). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 3. Install the transmission fluid fill plug. ^ Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4547 Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 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 transmission fluid cooler tubes and install a new transmission fluid cooler before placing the transmission in use. CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the transmission fluid cooling system or transmission could occur. 1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the transmission fluid cooler and tubes. 3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately in the following sequence. 1 Connect the pressure line to the transmission fluid cooler inlet tube. 2 Connect the return line to the transmission fluid cooler outlet tube. 3 Place the outlet end of the return line in the transmission fluid tank reservoir. 4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system. Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler tubes. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission Fluid Filter - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid drain plug and drain the transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4552 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. 5. Remove and discard the transmission fluid pan filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4553 Installation 1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4554 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. Install the transmission fluid drain plug. ^ Tighten to 26 Nm (19 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4555 7. Partially fill the transmission. Transmission Filter - In Line Transmission Filter - In Line NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or in-line transmission fluid filter kit. ^ If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4556 3. Using the special tool, disconnect the transmission fluid cooler connector. 4. Remove the section of the transmission fluid cooler tube at the second flare. ^ Clean and deburr the cut end of the transmission fluid cooler tube. 5. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 6. Remove the section of the transmission fluid cooler hose as illustrated. 7. CAUTION: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the transmission fluid filter indicates the direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in the transmission fluid cooler return line with the red arrow on the transmission fluid filter pointing away from the transmission fluid cooler and toward the transmission (the transmission fluid return line has transmission fluid coming out of the transmission fluid cooler going to the transmission). If the transmission fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a bend entering the transmission fluid filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal transmission damage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4557 Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a clamp. ^ Tighten the transmission fluid cooler hose clamp. 8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing ferrule hose assembly with 2 clamps. ^ Tighten the hose clamps. 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4558 Fluid Filter - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4559 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 transmission fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter seal is in the case, carefully remove the transmission fluid filter seal without scratching the case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4560 2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the transmission fluid filter seal with clean transmission fluid. 3. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4561 Install a new transmission fluid pan gasket if required. 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > NHTSA07V453000 > Sep > 07 > Recall 07V453000: A/T Cooler Line Bolt Torque Fluid Line/Hose: Recalls Recall 07V453000: A/T Cooler Line Bolt Torque MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2008 Ford/Explorer Sport Trac 2008 Mercury/Mountaineer 2008 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V453000 MFR'S REPORT DATE: August 28, 2007 COMPONENT: Power Train: Automatic Transmission: Cooling Unit and Lines POTENTIAL NUMBER OF UNITS AFFECTED: 1497 SUMMARY: On certain sport utility vehicles equipped with the 4.6l engine and 6R transmission, the bolt securing the transmission oil cooler line fittings at the transmission may not have been sufficiently torqued during vehicle assembly. AS A RESULT, THE BOLT MAY LOOSEN AND THE TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION, CAUSING A TRANSMISSION FLUID LEAK. CONSEQUENCE: If leaking transmission fluid contacts the catalytic converter, it may pose a risk of fire. REMEDY: Dealers will inspect and have the transmission cooler line attachment bolt tightened free of charge. The recall began on August 30, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S56. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential Technical Service Bulletin # 07S56 Date: 070822 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4574 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by August 22, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website by August 22, 2007. Owner names and addresses will be available by September 7, 2007. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4575 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. 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). ^ 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 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 are not required for this repair. Attachment III - Technical Information 1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the transmission. (See illustration.) NOTE: If cooler lines are leaking transmission fluid at the transmission attachment point, call Special Service Support Center. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4576 2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4577 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4578 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > NHTSA07V453000 > Sep > 07 > Recall 07V453000: A/T Cooler Line Bolt Torque Fluid Line/Hose: All Technical Service Bulletins Recall 07V453000: A/T Cooler Line Bolt Torque MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2008 Ford/Explorer Sport Trac 2008 Mercury/Mountaineer 2008 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V453000 MFR'S REPORT DATE: August 28, 2007 COMPONENT: Power Train: Automatic Transmission: Cooling Unit and Lines POTENTIAL NUMBER OF UNITS AFFECTED: 1497 SUMMARY: On certain sport utility vehicles equipped with the 4.6l engine and 6R transmission, the bolt securing the transmission oil cooler line fittings at the transmission may not have been sufficiently torqued during vehicle assembly. AS A RESULT, THE BOLT MAY LOOSEN AND THE TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION, CAUSING A TRANSMISSION FLUID LEAK. CONSEQUENCE: If leaking transmission fluid contacts the catalytic converter, it may pose a risk of fire. REMEDY: Dealers will inspect and have the transmission cooler line attachment bolt tightened free of charge. The recall began on August 30, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S56. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential Technical Service Bulletin # 07S56 Date: 070822 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4588 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by August 22, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website by August 22, 2007. Owner names and addresses will be available by September 7, 2007. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4589 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. 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). ^ 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 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 are not required for this repair. Attachment III - Technical Information 1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the transmission. (See illustration.) NOTE: If cooler lines are leaking transmission fluid at the transmission attachment point, call Special Service Support Center. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4590 2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4591 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4592 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 5R55S Transmission Fluid Cooler Tubes - 5R55S Removal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4595 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a backup wrench to hold the case fitting securely, disconnect the transmission fluid cooler tubes. 3. Remove the secondary latch from the cooler tube. 4. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 5. Remove the secondary latch from the transmission fluid cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4596 6. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission fluid cooler hose. 7. Remove the transmission fluid cooler tube bracket nut. 8. Remove the fluid cooler tube bracket from the stud. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4597 9. Remove the transmission cooler tubes from the vehicle. Installation 1. Install the transmission cooler tubes into the vehicle. 2. Install the transmission fluid cooler tube bracket onto the stud. 3. Verify the case fitting torque. ^ Tighten to 56 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4598 4. CAUTION: To prevent cross threading, all transmission fluid cooler tube nuts must be hand started before being tightened to specification. Using a backup wrench to hold the case fittings securely, install the transmission fluid cooler tubes. ^ Tighten to 40 Nm (30 lb-ft). 5. Install the transmission fluid cooler tube bracket nut. ^ Tighten to 25 Nm (18 lb-ft). 6. Connect the transmission fluid cooler tube to the transmission fluid cooler hose. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4599 7. Install the secondary latch. 8. Connect the transmission fluid cooler tube to the radiator. 9. Install the secondary latch. 10. Fill transmission fluid to the correct level using clean transmission fluid and inspect for leak. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4600 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 6R60 Transmission Fluid Cooler Tubes - 6R60 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4601 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4602 3. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 4. Remove the secondary latch from the transmission fluid cooler tube. 5. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission fluid cooler hose. 6. Remove the transmission fluid cooler tube bracket nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4603 7. If equipped, index-mark the front driveshaft to maintain driveshaft balance. 8. If equipped, remove the 4 U-joint strap bolts and remove the U-joint straps. ^ Discard the bolts. 9. Disconnect the engine oil low level sensor electrical connector and harness clips. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4604 10. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully remove them from the case. Remove the bolt and disconnect the transmission fluid cooler tubes from the transmission. 11. Remove and discard the 4 O-rings from the transmission fluid cooler tube ends. 12. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4605 2. Install 4 new O-rings on the transmission fluid cooler tube ends. 3. NOTE: Inspect the transmission case to make sure that the old O-rings are not stuck in the transmission case. Position the transmission fluid cooler tubes into the transmission, then install the bolt for the transmission cooler tube retainer. ^ Tighten to 25 Nm (18 lb-ft). 4. Install the transmission fluid cooler tube bracket and install the transmission fluid cooler tube bracket nut. ^ Tighten to 12 Nm (9 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4606 5. NOTE: Install new U-joint strap bolts. If new U-joint strap bolts are not available, coat the threads of the original U-joint strap bolts with Threadlock(R) and sealer. If removed, install the U-joint straps and 4 new U-joint strap bolts. ^ Tighten to 19 Nm (14 lb-ft). 6. Connect the engine oil low level sensor electrical connector and harness clips. 7. Connect the transmission fluid cooler tube to the radiator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4607 8. Install the secondary latch to the transmission fluid cooler tube at the radiator. 9. Connect the transmission fluid cooler tube to the transmission fluid cooler hose. 10. Install the secondary latch to the transmission fluid cooler tube at the cooler hose. 11. Fill the transmission fluid to the correct level, using clean transmission fluid, and inspect for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4608 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hoses Transmission Fluid Cooler Hoses Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4609 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Mountaineer 2. Remove the grille fasteners and the grille. Explorer 3. Remove the bumper cover. All vehicles 4. Remove the inner grille air deflector. 5. Push the lower air deflector down past the transmission fluid cooler. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4610 6. Disconnect the transmission fluid cooler hoses. ^ Remove and discard the transmission fluid cooler hoses and the clamps. 7. Remove the secondary latch from the transmission fluid cooler tube. 8. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission cooler hose. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4611 9. Remove the secondary latch from the transmission fluid cooler hose. 10. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid cooler hose from the radiator. 11. Remove the hoses from the retainer. Installation All vehicles 1. Install the hoses into the retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4612 2. Install the transmission fluid cooler hose to the radiator. 3. Install the secondary latch. 4. Install the transmission fluid cooler hose to the transmission fluid cooler tube. 5. Install the secondary latch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4613 6. NOTE: Clean the transmission fluid cooler tube stems with degreaser prior to installing the hoses. Using new hoses and clamps, install the new transmission fluid cooler hoses. 7. Push the lower air deflector back into place. 8. Install the inner grille air deflector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4614 Mountaineer 9. Install the grille and the fasteners. Explorer 10. Install the bumper cover. All vehicles 11. Fill the transmission fluid to the correct level using clean transmission fluid and inspect for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Fluid Pan: Specifications 5R55S - Automatic Transaxle/Transmission Transmission Fluid Pan Screws - 5R55S - Automatic Transaxle/Transmission ............................................. 11 Nm (8 lb-ft). in a crisscross sequence Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4619 Fluid Pan: Specifications 6R60 - Automatic Transaxle/Transmission Transmission Fluid Pan Screws - 6R60 - Automatic Transaxle/Transmission ................................................. 14 Nm (10 lb-ft). in a crisscross pattern Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission Fluid Pan: Service and Repair 5R55S - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid drain plug and drain the transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4622 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. 5. Remove and discard the transmission fluid pan filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4623 Installation 1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4624 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. Install the transmission fluid drain plug. ^ Tighten to 26 Nm (19 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4625 7. Partially fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4626 Fluid Pan: Service and Repair 6R60 - Automatic Transaxle/Transmission Fluid Pan, Gasket and Filter 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4627 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 transmission fluid filter may be reused if no excessive contamination is indicated. 1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter seal is in the case, carefully remove the transmission fluid filter seal without scratching the case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4628 2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the transmission fluid filter seal with clean transmission fluid. 3. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4629 Install a new transmission fluid pan gasket if required. 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). 7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4655 Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4671 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4672 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4673 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4674 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4675 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4676 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4677 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4678 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4679 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4684 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission Seals and Gaskets: Service and Repair 5R55S - Automatic Transaxle/Transmission Extension Housing Seal Extension Housing Seal - Four Wheel Drive (4WD) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4689 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transfer case assembly. 3. Using the special tools, remove the extension housing seal. Installation 1. NOTE: Make sure the extension housing seal is correctly installed onto the special tool and the garter spring is in the correct position. Using the special tool, install the extension housing seal. 2. Install the transfer case assembly. 3. Lower the vehicle. 4. Carry out the transmission fluid level check. See: Service and Repair/Procedures/Transmission Fluid Level Check Extension Housing Gasket Extension Housing Gasket - Four Wheel Drive (4WD) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4690 Extension Housing Gasket - Four Wheel Drive (4WD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Support the transmission with a suitable jack. 3. Remove the transfer case. 4. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing. Remove the extension housing. 5. Remove and discard the extension housing gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4691 Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the park pawl is installed correctly. 2. NOTE: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. ^ Tighten to 30 Nm (22 lb-ft). 3. Install the transfer case. 4. Remove the transmission support. 5. Carry out the transmission fluid level check. See: Service and Repair/Procedures/Transmission Fluid Level Check Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4692 Seals and Gaskets: Service and Repair 6R60 - Automatic Transaxle/Transmission Output Shaft Seal Output Shaft Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4693 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 output shaft flange nut, remove the stake to prevent damage to the output shaft. Remove and discard the output shaft flange nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4694 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4695 Installation RWD vehicles 1. Position a new output shaft seal. 2. Using the special tool, install the output shaft seal. 3. Install the output shaft flange. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4696 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4697 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 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield. 3. Disconnect the selector lever cable end. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4698 4. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed. 5. Remove the transmission fluid pan and allow the transmission fluid to drain. 6. Remove and discard the transmission fluid filter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4699 7. Remove the transmission fluid pan gasket. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4700 10. 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. 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 transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit. Pull the bulkhead electrical connector out of the transmission. 12. NOTE: During removal of the mechatronic, the thermal bypass valve, pump adapter seal and one or more center support seals may become dislodged. Save these components for re-use during assembly. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4701 13. Remove the park pawl abutment. 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 detent lever and the park rod as an assembly. 15. Remove and discard the manual control lever seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4702 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 control lever in the case. 1 Slide the manual control lever in the case. 2 Position the spacer in place while sliding the manual control lever into the spacer. 3 Position the manual valve inner detent lever while sliding the manual control lever and lining up the roll pin hole. 4 Install the roll pin. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4703 4. Position the manual lever and 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 pawl abutment. ^ Tighten to 10 Nm (89 lb-inch). 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4704 7. Verify the rubber adapter is in place. 8. Verify the thermal bypass valve is in the case. 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 11 bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4705 1 Align the manual valve and control lever linkage. 10. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-inch). 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. 12. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4706 13. Install a new transmission fluid filter. 14. NOTE: The fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if necessary. 15. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4707 16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 17. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable 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 selector lever 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. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4708 19. Using the transmission fluid refill procedure, fill and check the transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4714 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4715 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4716 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4717 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4718 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4719 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4720 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4721 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4722 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4723 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4724 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4725 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4726 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 4727 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4732 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4733 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4734 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4735 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4736 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4737 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4738 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4739 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4740 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4741 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4742 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4743 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4744 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4749 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4750 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4751 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4752 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4753 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4754 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4755 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4756 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4757 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4758 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4759 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4760 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4761 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4767 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4768 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4769 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4770 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4771 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4772 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4773 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4774 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4775 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4776 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4777 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4778 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4779 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 4782 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4783 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4787 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4790 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4791 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4792 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4793 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4794 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4795 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4796 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4797 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4798 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4799 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4800 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4801 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4802 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4803 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4804 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4805 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4806 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4807 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4808 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4809 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4810 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4811 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4812 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4817 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4818 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4819 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4822 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4823 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4824 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4825 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4826 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4827 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4828 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4829 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4830 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4831 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4832 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4833 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4834 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4835 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4836 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4839 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4840 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4841 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4842 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4843 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4844 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4845 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4846 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4847 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4848 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4849 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4850 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4851 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4852 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4853 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4854 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 4855 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4860 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4861 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4862 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4863 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4864 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4865 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4866 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4867 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4868 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4869 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4870 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4871 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 4872 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. 2. Disconnect the brake shift interlock actuator electrical connector. 3. Remove the screw and the brake shift interlock actuator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4877 Installation 1. Install the brake shift interlock actuator. 2. Connect the brake shift interlock actuator electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4882 Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4898 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4899 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4900 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4901 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4902 Shift Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4903 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4904 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4905 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4906 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Shifter A/T: Service and Repair Selector Lever Selector Lever Selector Lever Removal 1. Remove the front floor console. 2. Disconnect the selector lever cable from the selector lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4911 3. Disconnect the selector lever cable from the selector lever housing. 4. Disconnect the selector lever housing electrical connector. 5. Disconnect the wiring harness from the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4912 6. Remove the 4 nuts and remove the selector lever housing from the vehicle. Installation NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. 1. Install the selector lever housing. ^ Tighten to 9 Nm (80 lb-inch). 2. Connect the wiring harness to the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4913 3. Connect the selector lever housing electrical connector. 4. Install the selector lever cable onto the selector lever housing. 5. Connect the selector lever cable onto the selector lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4914 6. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4915 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Selector Lever Knob Removal 1. Remove the front floor console. 2. Disconnect the transmission control (TC) switch electrical connector and feed the wire through the selector lever housing. 3. Slide the selector lever knob lower trim cover downward. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4916 4. Remove the set screw and remove the selector lever knob while routing the TC switch harness out of the selector lever housing. Installation 1. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur. Install the selector lever knob and set screw while routing the TC switch harness through the selector lever housing. ^ Tighten to 3 Nm (27 lb-inch). 2. Slide the selector lever knob lower trim cover upward. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4917 3. Feed the wire through the selector lever housing and connect the TC switch electrical connector. 4. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4918 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Selector Lever Bezel Removal 1. Remove the front floor console. 2. Disconnect the transmission control (TC) switch electrical connector and feed the wire through the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4919 3. Slide the selector lever knob lower trim cover downward. 4. Remove the set screw and remove the selector lever knob while routing the TC switch harness out of the selector lever housing. 5. Remove the selector lever bezel from the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4920 Installation 1. Install the selector lever bezel onto the selector lever housing. 2. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur. Install the selector lever knob and set screw while routing the TC switch harness through the selector lever housing. ^ Tighten to 3 Nm (27 lb-inch). 3. Slide the selector lever lower trim cover upward. 4. Feed the wire through the selector lever housing and connect the TC switch electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4921 5. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S Shift Cable: Adjustments Selector Lever Cable Adjustment - 5R55S Selector Lever Cable Adjustment - 5R55S 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the selector lever in the PARK position. 3. Move the selector lever 3 detents. This should be the (D) position. 4. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. 5. Disconnect the selector lever cable end from the manual control lever. 6. Rotate the manual control lever clockwise until the travel stops. Then rotate the manual control lever counterclockwise 3 detents. This should be the (D) position. 7. With the selector lever cable end disconnected, unlock the tab on the selector lever cable end by sliding it up. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 4927 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Carry out the following adjustments on the selector lever cable end: 1 Make sure that the selector lever cable end slides forward and backward. 2 Connect the selector lever cable end onto the manual control lever. 3 Lock the selector lever cable end into place by pressing the lock tab down. 9. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever cable shield. 10. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 4928 Shift Cable: Adjustments Selector Lever Cable Adjustment - 6R60 Selector Lever Cable Adjustment - 6R60 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Place the selector lever in the PARK position. 3. Move the selector lever 3 detents. This should be the (D) position. 4. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the shield away from the boot. 5. Disconnect the selector lever cable from the manual control lever. 6. Rotate the manual control lever clockwise until the travel stops. Then rotate the manual control lever counterclockwise 3 detents. This should be the (D) position. 7. With the selector lever cable end disconnected, unlock the tab on the selector lever cable end by sliding it up. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 4929 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Carry out the following adjustments on the selector lever cable end: 1 Make sure that the selector lever cable end slides forward and backward. 2 Connect the selector lever cable end onto the manual control lever. 3 Lock the selector lever cable end into place by pressing the lock tab down. 9. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4930 Shift Cable: Service and Repair Selector Lever Cable Vehicles Equipped with a 6R60 Transmission Vehicles Equipped with a 6R60 Transmission Vehicles Equipped with a 5R55S Transmission Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4931 Vehicles Equipped with a 5R55S Transmission Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the center console left side panel. 3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4932 4. Disconnect the selector lever cable from the selector lever housing. 5. Pull the selector lever cable and grommet through the floorpan. Vehicles equipped with a 6R60 transmission 6. Remove the selector lever cable shield by prying on the selector lever shield closest to the boot, then sliding the shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4933 7. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever. 8. Disconnect the selector lever cable from the selector lever cable bracket and remove the selector lever cable. Vehicles equipped with a 5R55S transmission 9. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4934 10. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever. 11. Disconnect the selector lever cable from the bracket and remove the selector lever cable. Installation Vehicles equipped with a 6R60 transmission NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. 1. Install the selector lever cable into the selector lever cable bracket. 2. Connect the selector lever cable end onto the manual control lever and lock the lock tab. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4935 3. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever cable shield. Vehicles equipped with a 5R55S transmission NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. 4. Install the selector lever cable into the selector lever cable bracket. 5. Connect the selector lever cable end onto the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4936 6. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever cable shield. All vehicles 7. Push the selector lever cable and grommet through the floorpan. 8. Connect the selector lever cable onto the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4937 9. Connect the selector lever cable onto the selector lever. 10. Install the center console left side panel. 11. Verify the engine will start in PARK and NEUTRAL and the reversing lamps illuminate in REVERSE. If not, readjust the selector lever cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 5R55S - Automatic Transaxle/Transmission Torque Converter: Description and Operation 5R55S - Automatic Transaxle/Transmission Torque Converter The torque converter transmits and multiplies torque. The torque converter is a 4-element device: ^ Impeller assembly ^ Turbine and damper assembly ^ Reactor assembly ^ Clutch The standard torque converter components operate as follows: ^ Rotation of the converter housing and impeller set the transmission fluid in motion. ^ The turbine reacts to the transmission fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects transmission fluid going back into the impeller, allowing for torque multiplication. ^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 5R55S - Automatic Transaxle/Transmission > Page 4959 Torque Converter: Description and Operation 6R60 - Automatic Transaxle/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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission Torque Converter: Testing and Inspection 5R55S - Automatic Transaxle/Transmission Stall Speed Chart Stall Speed Chart Torque Converter 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. Torque Converter Contamination Inspection Torque Converter Contamination Inspection CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. NOTE: The torque converter drain plug and seal are not reusable. If equipped, discard the torque converter drain plug and seal, then install a new torque converter drain plug assembly. 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 transmission fluid. 3. Observe the color and odor of the transmission fluid. The transmission 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 (spec of any kind). Examine the transmission fluid for signs of antifreeze (gum or varnish). If particles are present in the transmission fluid or there is evidence of engine coolant or water, 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 transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the transmission fluid. Torque Converter Diagnosis Torque Converter Diagnosis Prior to installing a new torque converter, 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 or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer Concern. 3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test. See: Transmission Control Systems/Testing and Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 4962 Inspection/Component Tests and General Diagnostics/5R55S - Automatic Transaxle/Transmission/Torque Converter Operation Test 4. Carry out Diagnostic Procedures. ^ Run on-board diagnostics. See On-Board Diagnostics with scan tool. Refer to Diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. ^ Carry out the Line Pressure Test. Refer to Special Testing Procedures. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S Automatic Transaxle/Transmission/Special Testing Procedures ^ Carry out the Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S - Automatic Transaxle/Transmission/Stall Speed Test ^ Carry out the Diagnosis by Symptom Index. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as necessary before servicing the torque converter. Torque Converter Operation Test Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out the Quick Test. See On-Board Diagnostics with Scan Tool. Refer to Diagnostics. Check for DTCs. Refer to the Diagnostic Trouble Code (DTC) Charts. See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview See: Transmission Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. The 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, refer to Torque Converter Operation Concerns in Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom 6. If the vehicle stalls in (D) or MANUAL 2 at idle with vehicle at a stop, move the transmission range selector lever to MANUAL 1 position. If the vehicle stalls, refer to Diagnosis By Symptom, Torque Converter Operation Concerns. Repair as necessary. If the vehicle does not stall in (D), refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 4963 Torque Converter: Testing and Inspection 6R60 - Automatic Transaxle/Transmission Torque Converter 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. Torque Converter Contamination Inspection Torque Converter Contamination Inspection 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 red. 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 transmission fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the transmission 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 transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the transmission fluid. Torque Converter Diagnosis 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. See: 5R55S - Automatic Transaxle/Transmission/Torque Converter Operation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 4964 Test 4. Carry out diagnostic procedures. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom ^ Carry out on-board diagnostics. Refer to 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. Refer to Special Testing Procedures. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S - Automatic Transaxle/Transmission/Stall Speed Test ^ Carry out Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Use the Diagnosis by Symptom to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. Torque Converter Operation Test The Torque Converter Operation Test verifies that the torque converter clutch (TCC) control system and the torque converter are operating correctly. 1. Carry out Quick Test with 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 30% 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. For diagnosis of the following items, refer to Computers and Control Systems. ^ Spark plugs - check for cracks, high resistance or broken insulators ^ Plug wires ^ Fuel injector - filter may be plugged ^ Fuel contamination - engine driveability concerns ^ EGR valve - valve may let in too much exhaust gas and cause engine to run lean ^ Vacuum leak - engine will not get correct air/fuel mixture ^ 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4983 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4984 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4985 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4986 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4987 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential Technical Service Bulletin # 07S56 Date: 070822 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4996 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by August 22, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website by August 22, 2007. Owner names and addresses will be available by September 7, 2007. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4997 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. 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). ^ 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 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 are not required for this repair. Attachment III - Technical Information 1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the transmission. (See illustration.) NOTE: If cooler lines are leaking transmission fluid at the transmission attachment point, call Special Service Support Center. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4998 2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4999 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5000 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential Technical Service Bulletin # 07S56 Date: 070822 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5006 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by August 22, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website by August 22, 2007. Owner names and addresses will be available by September 7, 2007. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5007 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. 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). ^ 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 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 are not required for this repair. Attachment III - Technical Information 1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the transmission. (See illustration.) NOTE: If cooler lines are leaking transmission fluid at the transmission attachment point, call Special Service Support Center. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5008 2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5009 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5010 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications Transmission Cooler: Mechanical Specifications General Specifications General Specifications Torque Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 5013 Transmission Cooler: Capacity Specifications Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 5014 Transmission Cooler: Fluid Type Specifications Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Transmission Cooling Transmission Cooling CAUTION: Whenever a transmission has been disassembled to install new parts, a new transmission fluid cooler must be installed and the transmission fluid cooler tubes must be cleaned and backflushed. NOTE: Cleaning and backflushing the transmission fluid cooling system (along with normal cleaning and inspection procedures, as outlined during disassembly and assembly) will keep contamination from reentering the transmission and 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 in use. Inspection and Verification Inspection and Verification When transmission fluid leakage is found in the transmission fluid cooler, install a new transmission fluid cooler. When there is evidence of transmission assembly or transmission fluid contamination due to the following transmission failure modes, install a new transmission fluid cooler. ^ Major metallic failure ^ Multiple clutches or clutch plate failure ^ Sufficient component wear which results in metallic contamination If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom Chart - Noise, Vibration and Harshness (NVH). See: Symptom Related Diagnostic Procedures See: Symptom Related Diagnostic Procedures/Symptom Chart - Noise, Vibration and Harshness (NVH) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5017 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart - Transmission Cooling Symptom Chart - Transmission Cooling Symptom Chart - Transmission Cooling Symptom Chart - Noise, Vibration and Harshness (NVH) Symptom Chart - Noise, Vibration and Harshness (NVH) NOTE: Noise, vibration and harshness (NVH) symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to Vehicle/Testing and inspection. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to Vehicle/Testing and inspection for the next likely system and continue diagnosis. Symptom Chart - Noise, Vibration and Harshness (NVH) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5018 Transmission Cooler: Component Tests and General Diagnostics 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines. ^ Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Transmission Fluid Cooler Flow Test - 5R55S Transmission Fluid Cooler Flow Test - 5R55S 1. Refer to Automatic Transaxle/Transmission - 5R55S. 6R60 - Automatic Transaxle/Transmission Transmission Fluid Cooler Backflushing and Cleaning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5021 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 transmission fluid cooler tubes and install a new transmission fluid cooler before placing the transmission in use. CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the transmission fluid cooling system or transmission could occur. 1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the transmission fluid cooler and tubes. 3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately in the following sequence. 1 Connect the pressure line to the transmission fluid cooler inlet tube. 2 Connect the return line to the transmission fluid cooler outlet tube. 3 Place the outlet end of the return line in the transmission fluid tank reservoir. 4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system. Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler tubes. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5022 Transmission Cooler: Removal and Replacement Auxiliary Transmission Fluid Cooler Removal Mountaineer 1. Remove the grille fasteners and the grille. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5023 Explorer 2. Remove the bumper cover. All vehicles 3. Remove the inner grille air deflector. 4. Push the lower air deflector down past the transmission fluid cooler. 5. Disconnect the transmission fluid cooler hoses. ^ Remove and discard the transmission fluid cooler hoses and the clamps. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5024 6. Remove the upper transmission fluid cooler bolt. 7. Remove the lower transmission fluid cooler bolts and the transmission fluid cooler. Installation All vehicles 1. Install the transmission fluid cooler and the lower transmission fluid cooler bolts. ^ Tighten to 7 Nm (62 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5025 2. Install the upper transmission fluid cooler bolt. ^ Tighten to 7 Nm (62 lb-inch). 3. NOTE: Clean the transmission cooler tube stems with degreaser prior to installing the hoses. Using new hoses and clamps, install the new transmission fluid cooler hoses. 4. Push the lower air deflector back into place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5026 5. Install the inner grille air deflector. Mountaineer 6. Install the grille and the fasteners. Explorer 7. Install the bumper cover. All vehicles 8. Fill the transmission fluid to the correct level using clean transmission fluid and inspect the leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 5050 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5051 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Support Insulator -Four Wheel Drive (4WD) Transmission Support Insulator - Four Wheel Drive (4WD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate bolts and the skid plate. 3. Support the transmission with a transmission jack. 4. Remove the 2 transmission support insulator nuts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 5055 5. NOTE: Crossmember and exhaust system shown removed. NOTE: LH shown, RH similar. Remove the 2 transmission support insulator bolts. 6. Raise the transmission and remove the transmission support insulator. Installation 1. Install the transmission support insulator and the 2 transmission support insulator bolts. ^ Tighten to 90 Nm (66 lb-ft). 2. Lower the transmission and install the 2 transmission support insulator nuts. ^ Tighten to 90 Nm (66 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 5056 3. If equipped, install the skid plate and bolts. ^ Tighten to 24 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5060 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5077 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5078 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5079 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5080 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5081 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5082 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5083 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5084 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5085 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > Pressure Test - PC A, PC B - 5R55S Transmission Pressure Test Port: Locations Pressure Test - PC A, PC B - 5R55S Pressure Test - PC A, PC B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > Pressure Test - PC A, PC B - 5R55S > Page 5090 Transmission Pressure Test Port: Locations Pressure Test - PC C - 5R55S Pressure Test - PC C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5095 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5096 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5097 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5117 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5118 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5119 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5120 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5121 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5122 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5123 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5124 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5125 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5126 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5127 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5128 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5129 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5130 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5131 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5132 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5133 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations Valve Body: Locations Main Control Valve Body Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 5154 Valve Body: Diagrams Main Control Valve Body Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 5155 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Solenoid Body Assembly Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5158 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5159 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5160 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5161 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Main Control Valve Body Main Control Valve Body Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5162 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5163 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5164 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around the transmission solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5165 5. Remove the transmission fluid pan filter. 6. Remove the reverse servo assembly screws and the reverse servo assembly. 7. Remove the transmission control solenoid body screws and the transmission control solenoid body. 8. Remove the manual control valve detent spring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5166 9. Remove the main control valve body screws and the main control valve body. Installation 1. Install the special tools into the transmission case. 2. Using the special tools, install the main control valve body and loosely install the main control valve body screws. 1 Install the short main control valve body screw. 2 Install the main control valve body screw with the larger head. 3 Install the remaining main control valve body screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5167 3. Remove the special tools and loosely install the main control valve body screw. 4. Tighten the main control valve body screws in the sequence shown. ^ Tighten to 10 Nm (89 lb-inch). 5. Install the manual control valve detent spring. ^ Tighten to 10 Nm (89 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5168 6. Install the reverse servo assembly. Tighten the reverse servo assembly screws in 2 stages, in the sequence shown. ^ Stage 1: Tighten to 5 Nm (44 lb-inch). ^ Stage 2: Tighten to 11 Nm (8 lb-ft). 7. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. 8. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If it is damaged, transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in the sequence shown. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5169 9. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 10. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. 11. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5170 12. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 13. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above specification. NOTE: Always install new O-ring seals on the transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the transmission control solenoid body harness connector. ^ Tighten to 5 Nm (44 lb-inch). 14. Fill the transmission. 6R60 - Automatic Transaxle/Transmission Mechatronic Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5171 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed. 4. Remove the transmission fluid pan and allow the transmission fluid to drain. 5. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5172 6. Remove and discard the transmission fluid filter. 7. Pull the release tab and pull down on the bulkhead connector retainer. 8. 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. With the release tab down, pull the outer shell of the bulkhead electrical connector out of the TCM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5173 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. Pull the bulkhead electrical connector out of the transmission. 10. NOTE: During removal of the mechatronic, the thermal bypass valve, pump adapter seal and one or more center support seals may become dislodged. Save these components for re-use during assembly. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly. Installation NOTE: Before reinstalling 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. 1. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5174 2. Verify the rubber adapter is in place. 3. Verify the thermal bypass valve is in the case. 4. Position the mechatronic assembly in place and loosely install the 11 bolts. 1 Align the manual valve and control lever linkage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5175 5. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 6 Nm (53 lb-inch). 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5176 8. Install a new transmission fluid filter. 9. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. 10. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ^ Tighten to 14 Nm (10 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5177 11. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 12. Using the transmission fluid refill procedure, fill the transmission with clean 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5178 Valve Body: Overhaul Main Control Valve Body Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5179 Disassembly 1. NOTE: The valve body separator plate has a bonded gasket. Do not reuse. Discard the plate. Remove and discard the valve body separator plate. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5180 2. Remove the check balls. 3. NOTE: Refer to the disassembled view. Disassemble the main control valve body only if cleaning is required. Assembly 1. CAUTION: Do not lose parts when cleaning or repairing. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air. 2. CAUTION: Do not stone, file or sand the valves. This will remove the anodized finish and may result in further main control or transmission damage. After cleaning the main control valve body, carry out the following: ^ Inspect all valve and plug bores for scoring or burrs ^ Check all fluid passages for obstructions ^ Inspect all valves and plugs for burrs ^ Inspect all mating surfaces for burrs or distortion ^ Inspect all springs for distortion ^ Check all valves and plugs for free movement in their respective bores ^ Valves and plugs, when dry, must fall from their own weight into their respective bores ^ Roll the manual valve on a flat surface to check for a bent condition 3. Assemble the main control valve body. 4. Install the main control valve body check balls. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5181 5. NOTE: Use a new valve body separator plate for main control valve body installation. Using the special tools, install a new main control valve body separator plate. ^ Tighten to 7 Nm (62 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Wiring Harness: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 5190 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Wiring Harness: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 5196 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Hydraulic Hose, Clutch > Component Information > Tools and Equipment Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 2.7 pts. (1.3L) Rear Differential Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 3.5 pts. (1.7L) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5206 Fluid - Differential: Fluid Type Specifications Front Differential Front Differential Dana 30.............................................................................................................................................M otorcraft SAE 80W-90 Premium Rear Axle Lubricant Part Number......................................................................................................................................... ..XY-80W90-QL(US) / CXY-80W90-1L(CANADA) Specification......................................................................................................................................... .........................................................WSP-M2C197-A Rear Differential Rear Differential Ford 8.8 Inch Ring Gear.................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Part Number......................................................................................................................................X Y-75W-140-QL(US) / CXY-75W140-1L(CANADA) Specification......................................................................................................................................... ........................................WSL-M2C192-A and GL-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 5207 Fluid - Differential: Service and Repair Differential Draining and Filling Fluid Drain and Fill 1. Remove both the fill plug and the drain plug. ^ Drain the axle assembly. 2. Clean and install the drain plug. ^ Tighten to 34 Nm (25 lb-ft). 3. Fill the axle with 1.65L (3.5 pt) of axle lubricant to the bottom of the fill plug hole. 4. Clean and install the fill plug. ^ Tighten to 34 Nm (25 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Differential Output Shaft Bearing: Service and Repair Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5213 Removal 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the correct tools can result in early stub shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new stub shaft pilot bearing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5214 Place the stub shaft pilot bearing onto the special tools. 3. Install the stub shaft pilot bearing into the rear axle housing bore. 4. 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 stub shaft pilot bearing oil seal onto a suitable seal installer. 5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft pilot bearing oil seal flush in the differential housing. 6. Install the halfshaft assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5215 Differential Output Shaft Bearing: Service and Repair Dana 30 Front Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5216 Removal Both sides 1. Remove the halfshafts. Right side 2. Remove the axle shaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5217 Both sides 3. Using the special tool and a suitable slide hammer, remove the stub shaft oil seals. 4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings. 5. Clean the bearing and seal surfaces of any foreign material. Installation Right side 1. Using the special tools, install the stub shaft pilot bearing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5218 2. Using the special tools, install the stub shaft oil seals. 3. Install the axle shaft. Left side 4. Using the special tools, install the stub shaft bearing. 5. Using the special tools, install the stub shaft seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5219 Both sides 6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Pinion Flange: Service and Repair Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Drive Pinion Flange and Drive Pinion Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5224 Removal 1. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer kit or damage to the component may occur. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel brake disc. 3. Remove the rear driveshaft. 4. Install a Nm (lb-inch) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5225 5. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 7. Using the special tool, remove the pinion flange. 8. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping pliers and strike with a hammer to remove the drive pinion seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5226 Installation 1. If removed, lubricate the lips of the new drive pinion seal with grease. 2. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. If the drive pinion seal was removed, use the special tool to install a new drive pinion seal. 3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if necessary. 4. Lubricate the pinion flange splines with grease. 5. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 6. Using the special tools, install the pinion flange. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5227 7. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. Select the new pinion nut for installation. Install and hand-tighten the pinion nut. 8.8 In. Pinion Nut 8. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut or component damage may occur. Install the new pinion nut that is included in the collapsible spacer kit. Tighten the new pinion nut to set the drive pinion bearing preload. ^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-inch) torque wrench. ^ Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in. 9. Install the rear brake disc 10. Install the rear driveshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5228 Pinion Flange: Service and Repair Dana 30 Front Drive Axle/Differential Drive Pinion Flange and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5229 Removal NOTE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing preload during assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during the pinion bearing preload recording and adjustment. Remove the front tires and wheels. 3. Remove the front driveshaft. 4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose or damage to the component may occur. Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake caliper anchors as an assembly. ^ Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5230 5. Measure and record the pinion bearing preload. ^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation. 6. Index-mark the pinion flange and the pinion gear stem. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5231 8. Using the special tool, remove the pinion flange. 9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the pinion bearing cone, pinion nut counterbore and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged. 10. Using gripping pliers and a hammer, remove the drive pinion oil seal. 11. Remove the drive pinion oil slinger and the outer pinion bearing. 12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal bore. Installation 1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5232 3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant. Using the special tool, install the drive pinion oil seal. 4. CAUTION: Never install the pinion flange with power tools or damage to the component may occur. Align the index marks and using the special tool, install the pinion flange. 5. Install the new pinion nut. Only hand-tighten the pinion nut at this time. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5233 6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary or damage to the component may occur. Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing preload. ^ Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm torque wrench. The final reading must be 0.56 Nm (5 lb-inch) more than the initial reading taken during removal. 7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc brake caliper anchor bolts. ^ Tighten to 108 Nm (80 lb-ft). 8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the flange and cause the boot to tear. NOTE: Install the driveshaft with new bolts and washers and new bolts and U-joint retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer. Install the front driveshaft. 9. Install the front tires and wheels. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal Seals and Gaskets: Service and Repair Drive Pinion Flange and Drive Pinion Seal Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Drive Pinion Flange and Drive Pinion Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5238 Removal 1. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer kit or damage to the component may occur. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel brake disc. 3. Remove the rear driveshaft. 4. Install a Nm (lb-inch) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5239 5. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 7. Using the special tool, remove the pinion flange. 8. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping pliers and strike with a hammer to remove the drive pinion seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5240 Installation 1. If removed, lubricate the lips of the new drive pinion seal with grease. 2. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. If the drive pinion seal was removed, use the special tool to install a new drive pinion seal. 3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if necessary. 4. Lubricate the pinion flange splines with grease. 5. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 6. Using the special tools, install the pinion flange. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5241 7. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. Select the new pinion nut for installation. Install and hand-tighten the pinion nut. 8.8 In. Pinion Nut 8. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut or component damage may occur. Install the new pinion nut that is included in the collapsible spacer kit. Tighten the new pinion nut to set the drive pinion bearing preload. ^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-inch) torque wrench. ^ Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in. 9. Install the rear brake disc 10. Install the rear driveshaft. Dana 30 Front Drive Axle/Differential Drive Pinion Flange and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5242 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5243 Removal NOTE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing preload during assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during the pinion bearing preload recording and adjustment. Remove the front tires and wheels. 3. Remove the front driveshaft. 4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose or damage to the component may occur. Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake caliper anchors as an assembly. ^ Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5244 5. Measure and record the pinion bearing preload. ^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation. 6. Index-mark the pinion flange and the pinion gear stem. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5245 8. Using the special tool, remove the pinion flange. 9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the pinion bearing cone, pinion nut counterbore and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged. 10. Using gripping pliers and a hammer, remove the drive pinion oil seal. 11. Remove the drive pinion oil slinger and the outer pinion bearing. 12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal bore. Installation 1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5246 3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant. Using the special tool, install the drive pinion oil seal. 4. CAUTION: Never install the pinion flange with power tools or damage to the component may occur. Align the index marks and using the special tool, install the pinion flange. 5. Install the new pinion nut. Only hand-tighten the pinion nut at this time. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5247 6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary or damage to the component may occur. Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing preload. ^ Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm torque wrench. The final reading must be 0.56 Nm (5 lb-inch) more than the initial reading taken during removal. 7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc brake caliper anchor bolts. ^ Tighten to 108 Nm (80 lb-ft). 8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the flange and cause the boot to tear. NOTE: Install the driveshaft with new bolts and washers and new bolts and U-joint retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer. Install the front driveshaft. 9. Install the front tires and wheels. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5248 Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5249 Removal 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the correct tools can result in early stub shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new stub shaft pilot bearing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5250 Place the stub shaft pilot bearing onto the special tools. 3. Install the stub shaft pilot bearing into the rear axle housing bore. 4. 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 stub shaft pilot bearing oil seal onto a suitable seal installer. 5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft pilot bearing oil seal flush in the differential housing. 6. Install the halfshaft assembly. Dana 30 Front Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5251 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5252 Removal Both sides 1. Remove the halfshafts. Right side 2. Remove the axle shaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5253 Both sides 3. Using the special tool and a suitable slide hammer, remove the stub shaft oil seals. 4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings. 5. Clean the bearing and seal surfaces of any foreign material. Installation Right side 1. Using the special tools, install the stub shaft pilot bearing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5254 2. Using the special tools, install the stub shaft oil seals. 3. Install the axle shaft. Left side 4. Using the special tools, install the stub shaft bearing. 5. Using the special tools, install the stub shaft seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5255 Both sides 6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 General Specifications Torque Specifications Torque Specifications General Specifications General Specifications Torque Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5261 Axle Shaft Assembly: Capacity Specifications Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5262 Axle Shaft Assembly: Fluid Type Specifications Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 The front axle halfshafts consist of the following: ^ Inner constant velocity (CV) joints ^ Outer CV joints ^ Interconnecting shafts ^ A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together ^ A circlip that retains the splined inboard CV joint to the differential side gear on the LH halfshaft ^ A circlip that retains the splined RH inboard CV joint to the intermediate shaft ^ CV joint boot clamps ^ Convoluted CV joint boots ^ Tripod joint housings ^ Ball and cage housings The front axle halfshafts are driven by the differential side gears inside the front axle assembly or the RH axle shaft. Rotational torque is transferred from the stub shafts through the inner CV joint, intermediate shaft and outer CV joint to the outer stub shaft. The outboard stub shafts are splined to drive the wheel hubs. They are retained in the wheel hubs by special wheel hub nuts, which also control the wheel bearing preload. The LH halfshaft is splined on the inboard stub shaft and is retained in the differential side gear in the transaxle by a circlip. The RH halfshaft has internal splines which are driven by the axle shaft. The axle shaft has a circlip on the outboard end and is retained inside the inboard stub shaft. New circlips must be installed whenever they are removed. The CV joint mates the interconnecting shaft with the stub shaft. The joint allows for smooth rotation of the interconnecting shaft and the stub shafts. They also adjust for length variances and angle requirements as the vehicle goes through jounce and rebound. Handle all halfshaft components carefully during removal and installation and during various component disassembly and assembly procedures. Never pick up or hold the halfshaft only by the inboard or outboard CV joint. Do not overangle the CV joints. Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint housing. Never use a hammer to remove or install the halfshafts from the front hub. Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust components. Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint housing only. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Do not remove the outer CV joint by pulling on the interconnecting shaft. Inspect all machined surfaces and splines for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 5265 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts Rear Drive Halfshafts The rear drive halfshafts consist of the following: ^ Inner constant velocity (CV) joints ^ Outer CV joints ^ Interconnecting shafts ^ Convoluted CV joint boots ^ CV joint boot clamps ^ Special CV high-temperature grease ^ Tripod joint housings ^ Ball and cage housings ^ A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together ^ A circlip that retains the splined inboard CV joint to the differential side gear ^ The RH and LH halfshafts are different lengths, with the LH halfshaft being the longer of the 2. The rear drive halfshafts link the rear axle to the rear wheel hubs. The CV joints allow the halfshafts to rotate smoothly through the required changes in angles between the stationary axle and the varying angles of the rear wheels including jounce and rebound. The CV joints are either tri-lobed style or the caged ball type depending on inboard or outboard. New halfshaft components are available as kits containing grease, boots and clamps. Handle all halfshaft components carefully during removal and installation and during various component disassembly and assembly procedures. Never pick up or hold the halfshaft only by the inboard or outboard CV joint. Do not overangle the CV joints. Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint housing. Never use a hammer to remove or install the halfshafts from the hub. Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust components. Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint housing only. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Do not remove the outer CV joint by pulling on the interconnecting shaft. Inspect all machined surfaces and splines for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Page 5266 Axle Shaft Assembly: Testing and Inspection Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Driveline or GO to Symptom Chart - Noise, Vibration and Harshness (NVH). See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - Driveline See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - Noise, Vibration and Harshness (NVH) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5269 Removal and Installation Both halfshafts 1. CAUTION: Do not loosen the front axle wheel end nut until after the wheel and tire assembly are 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. Remove the front wheel and tire. 3. Remove and discard the front axle wheel end nut. ^ To install, tighten to 200 Nm (148 lb-ft). 4. NOTE: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5270 Remove the 2 disc brake caliper guide pin bolts and position the disc brake caliper aside. ^ To install, tighten to 33 Nm (24 lb-ft). ^ Using mechanic's wire, position the disc brake caliper aside. 5. CAUTION: Do not use a hammer to separate the outboard constant velocity (CV) joint from the hub. Damage to the threads and internal CV joint components can result. Using the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. 6. Remove the tie-rod nut. ^ To install, tighten to 70 Nm (52 lb-ft). 7. Using the special tool, separate the tie rod from the knuckle. 8. Remove the stabilizer bar link nut. ^ To install, tighten to 25 Nm (18 lb-ft). 9. Remove the upper ball joint nut. ^ To install, tighten to 69 Nm (51 lb-ft). 10. NOTE: Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV joint from its housing. Using the special tool, disconnect the upper ball joint from the knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5271 LH halfshaft 11. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard constant velocity (CV) joint housing. Using the special tool, disengage the LH CV joint housing from the side gear. 12. Remove the LH halfshaft. RH halfshaft 13. NOTE: Install a new retainer circlip on the outboard spline end of the axle shaft before reseating the axle shaft in the differential side gear. Pull the RH halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft. 14. Remove the RH halfshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5272 Both halfshafts 15. NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding. To install, reverse the removal procedure. Rear Drive Halfshafts Halfshaft Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5273 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5274 Removal and Installation 1. CAUTION: Do not loosen the rear axle wheel end nut until after the wheel and tire assembly are 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. Remove the rear wheel and tire. 3. Remove and discard the rear axle wheel end nut. ^ To install, tighten to 275 Nm (203 lb-ft). 4. CAUTION: Do not use a hammer to separate the rear axle halfshaft assembly from the hub. Damage to the threads and internal constant velocity (CV) joint components may result. Using the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. 5. Remove the brake cable retainer screw. ^ To install, tighten to 20 Nm (15 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5275 6. Remove and discard the outboard toe link nut and back out the bolt for clearance. ^ To install, tighten to 350 Nm (259 lb-ft) at curb ride height. 7. Remove and discard the lower arm outboard bolt. ^ To install, tighten to 275 Nm (203 lb-ft) at curb ride height. 8. Remove and discard the 3 wheel knuckle bolts. ^ To install, tighten to 275 Nm (203 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5276 9. Pivot the wheel knuckle assembly upward on the upper arm outboard bolt. ^ Loosen the upper arm bolt to prevent bushing damage. ^ To install, tighten to 275 Nm (203 lb-ft) at curb ride height. 10. Using the special tool, disengage the inboard CV joint housing from the differential side gear. 11. Remove the halfshaft assembly. 12. CAUTION: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Install and tighten the new axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the axle wheel end nut and lead to bearing failure. Always install a new axle wheel end nut, after loosening or when not tightened to specifications, in a continuous rotation. NOTE: Always install a new differential stub shaft seal whenever the halfshaft is removed. NOTE: Make sure the halfshaft is completely seated in the differential side gear by pushing the halfshaft into the rear axle assembly until an audible click is heard or a leak may occur from the axle assembly. NOTE: Apply the brake to keep the halfshaft from rotating. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5277 13. Carry out a rear wheel alignment. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5278 Axle Shaft Assembly: Overhaul Front Drive Halfshafts Halfshaft Disassembly 1. Remove the RH or LH halfshaft assembly. 2. For the inboard constant velocity (CV) joint, carry out the following: 1 Remove and discard the 2 boot clamps. 2 Remove the inboard CV joint housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5279 3. For the inboard CV joint, carry out the following: 1 Remove and discard the retainer circlip. 2 Slide the boot away from the CV joint. 4. Using a suitable 3-jaw puller, remove the CV joint. 5. Remove and discard the inner CV boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5280 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 2 boot clamps. 2 Remove and discard the boot. Assembly 1. Lubricate the outboard CV joint. 1 Pack the outboard CV joint with grease from the kit. ^ One-third of the grease must be installed in the joint with the remainder placed in the boot. 2 Spread the remaining grease evenly inside the boot. 2. Position the boot so the rib on the boot is located in the groove of the shaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5281 3. Position the outboard halfshaft boot and the outboard boot clamps. 1 Position the boot. 2 Position the 2 boot clamps. 4. Install the outboard CV boot clamps. 5. Position the inboard clamp and boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5282 6. Install the CV joint and snap ring on the halfshaft. 7. Install the stop ring. 8. Fill the inboard CV joint housing with grease from the kit. ^ One-half of the grease must be installed in the joint and the remainder placed in the boot. 9. Position the CV housing on the CV joint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5283 10. Position the inboard halfshaft boot and clamp. 1 Position the boot in the housing groove. 2 Position the boot clamp. 11. Set the halfshaft assembled length to specifications. 1 Measure the entire assembly length. 2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length. 3 Hold the inner joint to prevent the assembled length from changing and insert a small flat-blade screwdriver between the boot and the joint to equalize the pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5284 12. Using the special tool, install the boot clamps. 13. Install the RH or LH halfshaft assembly. Rear Drive Halfshafts Halfshaft Joint Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5285 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5286 Disassembly 1. Remove the halfshaft assembly. 2. For the inboard CV joint, carry out the following: 1 Remove and discard the boot clamps. 2 Remove the inboard CV joint housing. 3. For the inboard CV joint, carry out the following: 1 Remove and discard the retainer circlip. 2 Slide the boot away from the CV joint. 4. Using a suitable 3-jaw puller, remove the CV joint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5287 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. Assembly 1. For the outboard CV joint, carry out the following: 1 Slide the boot on the interconnecting shaft. 2 Pack the outboard CV joint with 225 g (7.93 oz) of grease. 3 Spread any remaining grease evenly inside the boot. 4 Install the boot by seating it in the groove in the CV joint housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5288 2. Using the special tool, install the boot clamps. 3. NOTE: Install a new circlip every time the halfshaft is removed from the axle. Install a new retainer circlip. 4. Remove and discard the inboard halfshaft excluder seal, if equipped. 5. For the inboard CV joint, carry out the following: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5289 1 Position the clamp on the interconnecting shaft. 2 Position the boot on the interconnecting shaft. 3 Install the tri-lobe insert. 6. Using the special tool, install the CV joint. 7. Install the retainer circlip. 8. For the inboard CV joint, carry out the following: 1 Pack the inboard CV joint housing with 250 g (8.82 oz) of grease. 2 Spread any remaining grease evenly inside the boot and CV joint. 3 Install the inboard CV joint housing, seating the boot in the groove in the housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5290 9. Set the halfshaft assembled length to specifications. 1 Measure the entire assembly length. 2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length. 3 Hold the inner joint to prevent the assembled length from changing, and insert a soft, flat tool between the boot and the joint to equalize the pressure. 10. Using the special tool, install both boot clamps. 11. Install the halfshaft assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5299 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5300 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5301 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5302 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise > Page 5307 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5313 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5314 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5315 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5316 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise > Page 5321 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5322 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-19-6 Date: 080929 Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5323 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Technical Service Bulletin # 08-19-3 Date: 080929 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5324 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5325 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5326 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5327 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5328 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5329 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5330 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5331 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5332 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 Technical Service Bulletin # 08-19-6 Date: 080929 Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5333 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5334 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Bearing and Wheel Hub Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5339 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 3. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5340 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5341 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 components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 lb-inch). 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5342 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut Axle Nut: Specifications Rear Axle Wheel End Nut Rear Axle Wheel End Nut .................................................................................................................... ................................................ 275 Nm (203 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 5348 Axle Nut: Specifications Rear Axle Halfshaft Nut Rear Axle Halfshaft Nut ....................................................................................................................... ................................................ 275 Nm (203 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 5349 Axle Nut: Specifications Front Axle Wheel End Nut Front Axle Wheel End Nut ................................................................................................................... ................................................ 200 Nm (148 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 5350 Axle Nut: Specifications Front Axle Halfshaft Nut Front Axle Halfshaft Nut ...................................................................................................................... ............................................... 250 Nm (184 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Driveshaft Center Bearing Driveshaft Center Bearing Disassembly NOTE: The driveshaft center bearing on driveshafts with constant velocity (CV) joint flanges are not serviced. If the driveshaft center bearing is worn or damaged, install a new driveshaft. 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft tube in a vise. Denting or localized fracturing may result causing driveshaft failure during vehicle operation. Position the center U-joint yoke ears in a vise so that the C-washer is pointing up and the front section is free to move. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5355 3. Loosen the bolt inside the center cardan joint enough to allow the C-washer to fall from under the bolt head. ^ To install, tighten to 37 Nm (27 lb-ft). 4. NOTE: Index-mark the front and rear driveshaft sections. NOTE: The rear section has a master splined shaft and yoke. NOTE: The bolt head will fit through the internal spline of the center cardan. Using a rubber mallet, separate the driveshaft sections. 5. Using a suitable puller, remove the driveshaft center bearing from the rear section. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5356 6. NOTE: Install the new center bearing with the 3 bend tabs and dust seal lip facing the front of the vehicle. To install, reverse the removal process. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Driveshaft - Front Removal and Installation CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft may pinch the boot between the driveshaft and damage the constant velocity (CV) joint flange which may cause the boot to tear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the front driveshaft to maintain driveshaft balance. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5361 3. Remove and discard the 6 CV flange bolts and 3 CV joint washers. ^ To install, tighten the new bolts to 30 Nm (22 lb-ft). 4. Remove the 4 U-joint strap bolts and remove the 2 U-joint straps. ^ Discard the bolts. ^ To install, tighten the new bolts to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5362 5. Remove the front driveshaft. 6. CAUTION: Tighten the constant velocity (CV) joint bolts evenly in a cross pattern or damage will occur to the CV joint. NOTE: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration (top box). Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housing as shown in the cut-away illustration (bottom box), install a new driveshaft. NOTE: The CV joint is not serviceable. Install a new driveshaft if damaged. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5363 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, One-Piece Driveshaft - Rear, One-Piece, Four Wheel Drive (4WD) Driveshaft - Rear, One-Piece, Four Wheel Drive (4WD) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate. 3. Index-mark the driveshaft flange to the transfer case rear output flange to maintain driveshaft balance. 4. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5364 5. Remove and discard the 4 driveshaft flange bolts. ^ To install, tighten the 4 new bolts to 112 Nm (83 lb-ft). 6. Remove and discard the 4 transfer case rear output flange bolts. ^ To install, tighten the 4 new bolts to 112 Nm (83 lb-ft). 7. NOTE: The driveshaft flange fits tightly on the axle pinion flange pilot and the transfer case output flange. Never hammer on the driveshaft, or any of its components, to disconnect the driveshaft flanges from the mating flanges. Pry only in the area shown with a suitable tool. Using a suitable tool as shown, disconnect the driveshaft flanges and remove the driveshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5365 8. NOTE: The driveshaft flanges fit tightly on the pinion flange pilots. To make sure that the driveshaft flanges seat squarely on the pinion flanges, tighten the driveshaft flange bolts evenly in a cross pattern. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5366 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Two-Piece Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD) Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD) 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 nuts from the driveshaft center bearing bracket. ^ To install, tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5367 3. Index-mark the constant velocity (CV) joint to the transfer case output flange. 4. Index-mark the rear universal joint flange to the differential pinion flange. 5. Remove and discard the 6 CV joint bolts and 3 CV joint washers. ^ To install, tighten the 6 new bolts to 30 Nm (22 lb-ft). 6. Remove and discard the 4 driveshaft flange bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5368 ^ To install, tighten the 4 new bolts to 112 Nm (83 lb-ft). 7. NOTE: Never hammer on the driveshaft, or any of its components, to disconnect the driveshaft flange from the differential pinion flange. Using a suitable tool, pry only in the area shown to separate the driveshaft flange and the differential pinion flange. 8. Slide the driveshaft toward the rear of the vehicle, while maneuvering the front section over the top of the vehicle frame crossmember and remove the driveshaft. 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5369 Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Removal 1. Remove the driveshaft. 2. Index mark the driveshaft on both sides of the driveshaft slip yoke boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5370 3. Remove and discard the 2 driveshaft slip yoke boot clamps. 4. Separate the driveshaft. 5. Remove the driveshaft slip yoke boot. Installation 1. NOTE: Grease both ends of the driveshaft. Position the driveshaft slip yoke boot and the 2 driveshaft slip yoke boot clamps on one end of the driveshaft. 2. Align the index marks and connect the driveshaft. 3. Using the special tool, install the new driveshaft slip yoke boot. 4. Install the driveshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate Bolts ..................................................................................................................................... ...................................................... 80 Nm (59 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5374 Flex Plate: Testing and Inspection Flexplate Inspection 1. Inspect the flexplate for: 1 Any cracks. 2 Worn ring gear teeth. 3 Chipped or cracked ring gear teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5375 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 6 bolts and the flexplate. ^ To install, tighten to 80 Nm (59 lb-ft) in the sequence shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5376 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5390 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5395 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5398 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5399 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5400 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5407 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5408 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5409 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5410 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5411 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5412 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5413 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5414 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5415 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5416 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5417 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5418 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5419 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5420 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5425 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5426 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5427 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5428 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5429 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5430 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5431 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5432 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5433 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5434 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5435 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5436 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5437 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5442 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5443 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5444 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5445 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5446 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5447 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5448 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5449 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5450 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5451 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5452 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5453 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5454 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5460 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5461 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5462 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5463 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5464 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5465 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5466 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5467 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5468 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5469 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5470 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5471 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5472 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 5475 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5476 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5480 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5483 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5484 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5485 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5486 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5487 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5488 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5489 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5490 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5491 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5492 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5493 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5494 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5495 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5496 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5497 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5498 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5499 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5500 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5501 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5502 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5503 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5504 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5505 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5510 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5511 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5512 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5515 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5516 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5517 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5518 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5519 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5520 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5521 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5522 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5523 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5524 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5525 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5526 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5527 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5528 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5529 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5532 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5533 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5534 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5535 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5536 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5537 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5538 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5539 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5540 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5541 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5542 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5543 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5544 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5545 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5546 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5547 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5548 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5553 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5554 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5555 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5556 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5557 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5558 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5559 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5560 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5561 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5562 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5563 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5564 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5565 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5570 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5571 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5572 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair Transfer Case Actuator: Service and Repair Transfer Case Shift Motor Removal and Installation 1. With the ignition ON, press the 4X4 HIGH button on the mode select switch (MSS). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the 3 heat shield bolts and the heat shield. ^ To install, tighten to 16 Nm (12 lb-ft). 4. Disconnect the transfer case shift motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 5578 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. ^ To install, tighten to 10 Nm (89 lb-inch). 7. To install, reverse the removal procedure. ^ Apply a coat of multi-purpose grease to the transfer case shift motor bolts. ^ Apply a thin coat of silicone sealant to the shift motor sealing surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5582 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5585 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5586 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5587 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... ................................................. 1.5 Quarts (1.4 Liters) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5592 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid.............................................................................................................................. ...................................Motorcraft Transfer Case Fluid Part Number......................................................................................................................................... ...........................................................................XL-12 Specification......................................................................................................................................... ..........................................................ESP-M2C166-H Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5593 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling 1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: Position a suitable drain pan under the transfer case. Remove the drain plug and drain the fluid. 2. Clean and install the drain plug. ^ To install, tighten to 20 Nm (15 lb-ft). 3. CAUTION: Incorrect fluid fill can result in transfer case failure. NOTE: Fill the transfer case with the vehicle on a level surface. Make sure the fluid is level with the filler opening for the correct fluid level. Clean the area around the fill plug. Remove the fill plug. Using a suitable oil suction gun, fill the transfer case to the correct level with the specified fluid. 4. Clean and install the fill plug. ^ To install, tighten to 15 Nm (11 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5597 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5598 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5599 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5604 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5607 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 5608 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 5609 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal and Installation 1. With the transmission in NEUTRAL, position it on a hoist. 2. Index-mark the rear output flange and the driveshaft yoke. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 5613 3. NOTE: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer. Remove the 4 driveshaft yoke bolts. ^ To install, tighten to 112 Nm (83 lb-ft) evenly in a cross pattern. 4. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange or damage to the components can occur. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange. 5. Position the driveshaft aside and support with mechanic's wire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 5614 6. Using the special tool to hold the output flange, remove the nut. ^ To install, tighten to 355 Nm (262 lb-ft). 7. Remove the output shaft yoke washer. 8. Using the special tool, remove the rear output shaft flange. 9. Remove and discard the rear output shaft flange oil seal. 10. Using the special tools, remove the rear output shaft oil seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 5615 11. Using the special tool, install a new rear output shaft oil seal. 12. To install, reverse the removal procedure. ^ Always install a new rear output shaft flange oil seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5620 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5621 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5622 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair Transfer Case Actuator: Service and Repair Transfer Case Shift Motor Removal and Installation 1. With the ignition ON, press the 4X4 HIGH button on the mode select switch (MSS). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the 3 heat shield bolts and the heat shield. ^ To install, tighten to 16 Nm (12 lb-ft). 4. Disconnect the transfer case shift motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 5626 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. ^ To install, tighten to 10 Nm (89 lb-inch). 7. To install, reverse the removal procedure. ^ Apply a coat of multi-purpose grease to the transfer case shift motor bolts. ^ Apply a thin coat of silicone sealant to the shift motor sealing surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 5634 Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5637 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5638 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5639 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5640 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5641 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5642 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5643 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5644 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5645 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5646 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5647 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5648 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5649 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5650 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5651 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5652 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5653 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5654 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5655 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5656 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5657 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5658 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. 2. Disconnect the brake shift interlock actuator electrical connector. 3. Remove the screw and the brake shift interlock actuator. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5662 Installation 1. Install the brake shift interlock actuator. 2. Connect the brake shift interlock actuator electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission Solenoid Operation Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 5667 Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5670 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5671 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5672 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5673 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5674 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5675 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5676 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5677 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5678 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5679 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5680 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5681 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5682 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5683 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use the following shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5684 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5685 SSA, SSB SSC, SSD Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5686 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5687 Shift Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5688 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5689 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5690 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5691 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Application Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5697 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5698 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5699 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5700 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5701 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5702 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5703 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5704 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5705 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5706 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5707 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5708 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5709 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5710 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5711 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug and drain the transmission fluid. 3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. Disconnect the transmission control solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5712 5. Remove the transmission fluid pan filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with clean transmission fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5713 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. ^ Tighten to 8 Nm (71 lb-inch). 3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with clean transmission fluid. NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the transmission fluid pan filter. Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^ Tighten to 10 Nm (89 lb-inch). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5714 5. Tighten the transmission fluid pan screws in a crisscross sequence. ^ Tighten to 11 Nm (8 lb-ft). 6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around transmission control solenoid body harness connector to prevent contamination of the transmission control solenoid body harness connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. ^ Tighten to 5 Nm (44 lb-inch). 7. Fill the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair Transfer Case Actuator: Service and Repair Transfer Case Shift Motor Removal and Installation 1. With the ignition ON, press the 4X4 HIGH button on the mode select switch (MSS). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the 3 heat shield bolts and the heat shield. ^ To install, tighten to 16 Nm (12 lb-ft). 4. Disconnect the transfer case shift motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 5719 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. ^ To install, tighten to 10 Nm (89 lb-inch). 7. To install, reverse the removal procedure. ^ Apply a coat of multi-purpose grease to the transfer case shift motor bolts. ^ Apply a thin coat of silicone sealant to the shift motor sealing surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Locations View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 5730 C199 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Control Module: Locations View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5735 View 151-12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module C281A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module > Page 5738 C281B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > 4X4 Control Module > Page 5739 C2260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Page 5740 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 2. Open the glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4. Disconnect the electrical connectors. 5. Remove the 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5747 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5748 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5749 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5750 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5751 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5752 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5753 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5754 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5755 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5756 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5757 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5758 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5759 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5760 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5765 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5766 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5767 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5768 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5769 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5770 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5771 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5772 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5773 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5774 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5775 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5776 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5777 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5782 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5783 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5784 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5785 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5786 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5787 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5788 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5789 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5790 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5791 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5792 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5793 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5794 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5800 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5801 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5802 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5803 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5804 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5805 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5806 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5807 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5808 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5809 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5810 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5811 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5812 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 5815 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5816 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob. Installation 1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5820 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5823 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5824 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5825 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5826 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5827 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5828 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5829 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5830 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5831 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5832 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5833 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5834 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5835 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5836 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5837 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment - 5R55S Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5838 5. Remove the selector lever cable end from the manual control lever. 6. Remove the outer manual control lever nut and the manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5839 9. Install the outer manual lever and nut. ^ Tighten to 48 Nm (35 lb-ft). 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5840 12. Move the rubber boot back over the TR electrical connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5841 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5842 3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical connector. 4. Disconnect the digital TR sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. 6. Remove the outer manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5843 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5844 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 lb-ft). 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5845 6. Move the rubber boot back over the TR sensor electrical connector. 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5850 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5851 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5852 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5855 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5856 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5857 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5858 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5859 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5860 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5861 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5862 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5863 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5864 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5865 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5866 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5867 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5868 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5869 C164 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5872 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5873 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5874 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the intermediate shaft speed sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5875 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5876 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5877 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5878 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5879 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the OSS sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5880 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. ^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5881 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever cable bracket. ^ Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5882 7. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5883 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5884 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the selector lever cable shield away from the boot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5885 6. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5886 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 lb-ft). 2. Connect the TSS sensor 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable and selector lever bracket. ^ Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5887 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5888 7. Connect the front driveshaft to the front differential. ^ Tighten to 19 Nm (14 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5893 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5894 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5895 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5896 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5897 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5898 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5899 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5900 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5901 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5902 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5903 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5904 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5905 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5910 C284 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5911 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bezel. 3. With the center console cover open, remove the floor console center finish panel screws. 4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical connector. 5. Remove the floor console center finish panel. 6. Disconnect the electrical connector(s). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5912 7. Disengage the locking tangs and remove the mode select switch (MSS) from the instrument panel center finish panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 5918 C3073 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 5919 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 5920 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Diagrams C126 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5927 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5928 Electronic Brake Control Module: Diagrams C155 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5929 C155 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5930 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Programmable Module Installation in Information Bus (Module Configuration). 1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 lb-in). 3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the hydraulic control unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair Hydraulic Assembly: Service and Repair Hydraulic Control Unit (HCU) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > Page 5934 Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious 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 battery tray. 3. Disconnect the ABS module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 2 master cylinder primary and secondary brake tube-to-hydraulic control unit (HCU) fittings and position both brake tubes aside. ^ To install, tighten to 23 Nm (17 lb-ft). 5. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 brake tube-to-HCU extension tube fittings. ^ To install, tighten to 18 Nm (13 lb-ft). 6. Remove the 3 HCU bracket-to-frame nuts. ^ To install, tighten to 23 Nm (17 lb-ft). 7. Remove the HCU assembly. 8. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 HCU extension tube-to-HCU fittings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > Page 5935 ^ To install, tighten to 18 Nm (13 lb-ft). 9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. ^ To install, tighten to 9 Nm (80 lb-in). 10. Remove the HCU bracket-to-HCU bolt and the HCU bracket. ^ To install, tighten to 9 Nm (80 lb-in). 11. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Page 5939 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5946 C280 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5947 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 lb-in). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5948 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5953 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5954 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5955 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5956 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5957 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5958 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5959 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 5962 C160 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 5963 C440 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 5964 C426 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5967 ^ To install, tighten to 17 Nm (13 lb-ft). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 5968 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear 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 wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Page 5972 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5981 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5987 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5993 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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: This procedure is only required when a new hydraulic control unit (HCU) is installed. NOTE: When any part of the hydraulic system is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 5996 Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter 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 entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 5997 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 at least 2 times and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft). 6. Bleed the brake system. Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 5998 4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap. ^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in). ^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 5999 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure Bleed WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). 1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed new, carry out the Brake System Pressure Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System Bleed Procedure. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6000 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. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 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: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6001 ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Pedal Assy: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6010 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Pedal Assy: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6016 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Brake Pedal and Bracket Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6019 Removal 1. NOTE: If equipped with adjustable pedals, when removing the adjustable pedal assembly, make sure the pedals are adjusted to the full forward position. Depower the supplemental restraint system (SRS). For additional information, refer to Air Bag Systems. 2. CAUTION: Do not service the brake pedal without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Remove the stoplamp switch. For additional information, refer to Lighting and Horns. 3. Remove the speed control deactivator switch. For additional information, refer to Cruise Control. 4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster push rod clevis locking pin is removed, a new booster push rod clevis locking pin should be used. NOTE: Remove the clevis locking pin by squeezing the locking tabs and pulling outward on the opposite end. Remove the booster push rod clevis locking pin and discard. 5. Disconnect the brake booster rod from the brake pedal and position aside. 6. If equipped with power adjustable pedals, disconnect the adjustable pedal motor electrical connector. 7. If equipped with adjustable pedals, disconnect the accelerator pedal motor electrical connector. 8. Remove and discard the 2 brake pedal bracket bolts. 9. Remove and discard the 4 brake booster nuts. 10. Position the brake master cylinder and brake booster assembly forward to allow the brake pedal assembly to clear the studs. 11. Remove the 3 accelerator pedal bracket nuts. 12. Remove the 2 steering column opening cover screws and the steering column opening cover panel. 13. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence the steering column shaft has rotated, the clockspring must be removed and centered. For additional information, refer to Air Bag Systems. Secure the steering wheel using a suitable holding device. 14. Remove the steering column shaft bolt and disconnect the steering column shaft from the steering column. 15. Remove the brake pedal assembly from the vehicle. Installation 1. Position the brake pedal assembly in the vehicle. 2. Position the brake master cylinder and brake booster assembly into the brake pedal bracket assembly. 3. Install the 4 new brake booster nuts. ^ Tighten to 22 Nm (16 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6020 4. Install the 2 brake pedal bracket bolts. ^ Tighten to 22 Nm (16 lb-ft). 5. Install the 3 accelerator pedal bracket nuts. ^ Tighten to 7 Nm (62 lb-in). 6. If equipped with power adjustable pedals, connect the adjustable pedal motor electrical connector. 7. If equipped with adjustable pedals, connect the accelerator pedal electrical connector. 8. Position the brake booster push rod to the brake pedal. 9. Install the new booster push rod clevis locking pin. 10. Connect the steering column to the steering column shaft and install the bolt. ^ Tighten to 30 Nm (22 lb-ft). 11. Position the steering column opening cover and install the 2 screws. 12. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches. Install the stoplamp switch. 13. Install the speed control deactivator switch. 14. Repower the SRS. For additional information, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6021 Brake Pedal Assy: Service and Repair Brake Pedal Motor Brake Pedal Motor Removal and Installation 1. Disconnect the accelerator and brake pedal drive cables from the adjustable pedal motor. 2. Disconnect the adjustable pedal motor electrical connector. 3. Remove the 2 adjustable pedal motor screws and then remove the adjustable pedal motor and drive cables as an assembly. ^ To install, tighten to 3 Nm (27 lb-in). 4. NOTE: Make sure the brake pedal and the accelerator pedal are in the same position before connecting the drive cable to the adjustable pedals. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6031 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6032 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6038 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6039 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6042 ^ Cap the fluid ports. 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. Remove the 2 brake caliper guide pin bolts and the brake caliper. ^ If leaks or damaged boots are found, install a new brake caliper. Installation 1. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 lb-ft). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6043 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6044 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the wheel and tire. 2. Remove the brake flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position the brake caliper and install the 2 guide pin brake caliper bolts. ^ Tighten to 32 Nm (24 lb-ft). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 4. Bleed the brake caliper. 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6045 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and remove the brake caliper anchor plate. ^ To install, tighten to 165 Nm (122 lb-ft). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Pad: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6054 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6055 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Pad: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6061 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6062 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 6063 Brake Pad: Specifications Brake Pads Maximum taper wear (in any direction) ................................................................................................................................................ 3.0 mm (0.118 in) Minimum thickness .............................................................................................................. ................................................................. 3.0 mm (0.118 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6066 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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 brake fluid until the brake master cylinder reservoir is 1/2 full. 2. Remove the wheel and tire. 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 4. Inspect the brake pads for wear and contamination. 5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the brake pads and clips. ^ Discard the clips. Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: One brake disc pad kit contains the pads and pad clips required for both sides. Install the new brake pad clips and the brake pads. 2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. Using a C-clamp and a worn brake pad, compress the disc brake caliper pistons into the caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6067 3. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 lb-ft). 4. Fill the brake master cylinder reservoir with clean brake fluid. 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6068 Brake Pad: Service and Repair Rear Brake Pads Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6069 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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. Remove the wheel and tire. 3. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. 4. Inspect the brake pads for wear and contamination. 5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the 2 brake pads. ^ Discard the brake pad clips. Installation 1. NOTE: One brake disc pad kit contains the linings required for both sides. Install the brake pad clips and brake pads. 2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. If installing new brake pads, using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the caliper. 3. Position the brake caliper and install the 2 brake caliper guide pin bolts. ^ Tighten to 32 Nm (24 lb-ft). 4. Fill the brake master cylinder reservoir with clean, specified brake fluid. 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Brake Disc Minimum thickness .............................................................................................................................. ............................................... 28.5 mm (1.122 in) Minimum thickness to machine .......................................................................................................................................................... 29.10 mm (1.145 in) Rear Brake Disc Minimum thickness .............................................................................................................................. ................................................ 11.0 mm (0.433 in) Minimum thickness to machine ............................................................................................................................................................ 11.6 mm (0.456 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Disc Machining NOTE: Do not use a bench lathe to machine the brake discs. NOTE: Read the entire operating manual and/or 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 tube 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, carry out the steps in the following order. 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 marks and install the brake disc on the hub. 3. Machine the brake disc using an on-vehicle brake lathe. Carry out the steps in the following order. 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 in), maximum is 0.08 mm (0.003 in). 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 in). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. 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 carry out the steps in the following order: 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6075 Brake Rotor/Disc: Removal and Replacement Disc Removal and Installation, Front Brake Disc Removal 1. CAUTION: Do not allow the brake caliper, brake pads and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper anchor plate bolts and position the brake caliper, brake pads and anchor plate assembly aside. ^ Support the caliper, brake pads and anchor plate assembly using mechanic's wire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6076 2. NOTE: If the brake disc cannot be removed easily, apply rust penetrant on the brake disc-to-hub mating surfaces. Remove the brake disc. Installation 1. Clean any rust or foreign material from brake disc and wheel hub. ^ Use parts cleaner to clean the front brake disc and hub surfaces. 2. Apply a thin coat of anti-seize lubricant to the hub flange. 3. Install the brake disc. 4. Position the brake caliper, brake pads and brake caliper anchor plate assembly and install the 2 brake caliper anchor plate bolts. ^ Tighten to 165 Nm (122 lb-ft). Disc Removal and Installation, Rear Brake Disc Removal 1. Remove the wheel and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6077 2. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. CAUTION: Do not allow the brake 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 bolts, position the caliper and pads aside as an assembly. ^ Support the caliper and brake pad assembly using mechanic's wire. 3. NOTE: If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole knockout panel or access plug and contract the parking brake shoe and lining. NOTE: If the brake disc cannot be removed easily, apply penetrating lock lubricant on the brake disc-to-hub mating surfaces. Remove the brake disc. Installation NOTE: If the adjustment hole knockout panel or access plug was removed, it is necessary to install an access plug to prevent the entry of contaminants. 1. Clean any rust or foreign material from brake disc and wheel hub. ^ Use parts cleaner to clean the front brake disc and hub surfaces. 2. Install the brake disc. 3. Position the brake caliper and brake pad assembly. Install the 2 brake caliper guide pin bolts. ^ Tighten to 32 Nm (24 lb-ft). 4. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Shield Removal and Installation, Front Brake Disc Shield Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6078 Removal and Installation 1. Remove the brake disc. 2. Remove and discard the 4 brake disc shield bolts. ^ To install, tighten new bolts to 8 Nm (71 lb-in). 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Shield Removal and Installation, Rear Brake Disc Shield Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6079 Removal 1. Remove the parking brake shoes. 2. Remove the brake disc shield bolts. 3. Cut the shield at the perforations and remove the brake disc shield halves. Installation 1. NOTE: If installing a new brake disc shield, cut the new shield in half at the perforations. Position the brake disc shield halves and install 2 bolts in each half. ^ Tighten to 8 Nm (71 lb-in). 2. Install the parking brake shoes. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6089 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6095 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6101 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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: This procedure is only required when a new hydraulic control unit (HCU) is installed. NOTE: When any part of the hydraulic system is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6104 Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter 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 entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6105 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 at least 2 times and then hold firm pressure on the brake pedal. 2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft). 6. Bleed the brake system. Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6106 4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap. ^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in). ^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6107 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure Bleed WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). 1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed new, carry out the Brake System Pressure Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System Bleed Procedure. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6108 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. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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 is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 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: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6109 ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6118 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6119 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6125 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6126 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6129 ^ Cap the fluid ports. 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. Remove the 2 brake caliper guide pin bolts and the brake caliper. ^ If leaks or damaged boots are found, install a new brake caliper. Installation 1. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 lb-ft). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6130 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6131 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the wheel and tire. 2. Remove the brake flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position the brake caliper and install the 2 guide pin brake caliper bolts. ^ Tighten to 32 Nm (24 lb-ft). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 4. Bleed the brake caliper. 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6132 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and remove the brake caliper anchor plate. ^ To install, tighten to 165 Nm (122 lb-ft). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Part Number ................................................................................................................................ ................................................... PM-1 or PM-1-C Ford Specification ...................................................................................................................................................... ESA-M6C25-A or WSS-M6C62-A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6139 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6140 C124 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Brake Hose/Line: Service and Repair Front Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the brake flexible hose flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 lb-ft). ^ Use 2 new copper washers. 2. Disconnect the brake tube fitting from the brake flexible hose. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 6145 ^ To install, tighten to 18 Nm (13 lb-ft). 3. Remove the brake flexible hose retaining clip and the brake flexible hose. 4. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 6146 Brake Hose/Line: Service and Repair Rear Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 lb-ft). 3. Disconnect the brake tube fitting from the brake flexible hose. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 6147 ^ To install, tighten to 18 Nm (13 lb-ft). 4. Remove the brake flexible hose bracket bolt and the brake hose. ^ To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. ^ Bleed the brake caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair Hydraulic Assembly: Service and Repair Hydraulic Control Unit (HCU) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > Page 6151 Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious 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 battery tray. 3. Disconnect the ABS module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 2 master cylinder primary and secondary brake tube-to-hydraulic control unit (HCU) fittings and position both brake tubes aside. ^ To install, tighten to 23 Nm (17 lb-ft). 5. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 brake tube-to-HCU extension tube fittings. ^ To install, tighten to 18 Nm (13 lb-ft). 6. Remove the 3 HCU bracket-to-frame nuts. ^ To install, tighten to 23 Nm (17 lb-ft). 7. Remove the HCU assembly. 8. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 HCU extension tube-to-HCU fittings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > Page 6152 ^ To install, tighten to 18 Nm (13 lb-ft). 9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. ^ To install, tighten to 9 Nm (80 lb-in). 10. Remove the HCU bracket-to-HCU bolt and the HCU bracket. ^ To install, tighten to 9 Nm (80 lb-in). 11. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Bypass Condition Brake Master Cylinder - Bypass Condition 1. Disconnect the brake tubes from the master cylinder. 2. Plug the outlet ports of the master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 6157 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port Brake Master Cylinder - Compensator Port The purpose of the compensator ports in the brake master cylinder is to: ^ supply additional brake fluid from the brake master cylinder reservoir needed by the brake system due to brake lining wear. ^ allow brake fluid to return to the brake master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight turbulence in the brake master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. If clogged compensator ports are suspected, proceed as follows: 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair. 2. With the brakes released, attempt to rotate each wheel and check for any brake drag. ^ If an excessive amount of brake drag exists at all 4 wheels, continue with the test. ^ If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake caliper, brake wheel cylinder or parking brake component. Repair or install new components as necessary. 3. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not partially applied. 4. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster. 5. With the brakes released, attempt to rotate each wheel and check for any brake drag. ^ If the brake drag is no longer present, install a new brake booster. ^ If the brake drag is still present, install a new master cylinder. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6158 Brake Master Cylinder: Service and Repair Brake Master Cylinder Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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 serious 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. Use a suitable suction device to drain the brake master cylinder reservoir. 2. Disconnect the brake fluid level warning switch electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6159 3. Disconnect the 2 brake tube fittings from the brake master cylinder. ^ To install, tighten to 18 Nm (13 lb-ft). 4. Remove the 2 nuts, the brake master cylinder and the square cut seal. ^ To install, tighten to 25 Nm (18 lb-ft). 5. NOTE: Make sure that the square cut seal is properly installed or incorrect brake pedal feel can occur. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 in) x 150 mm (5.9 in) retainer pin can be inserted. 3. NOTE: 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. Disconnect the cable-to-cable connector clip. 4. To reload the tension on the parking brake cable, follow the release procedure in reverse. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6165 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Removal and Installation 1. Release the parking brake cable tension. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Remove the wire form bolt. ^ To install, tighten to 23 Nm (17 lb-ft). 4. Remove the bracket bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6166 ^ To install, tighten to 23 Nm (17 lb-ft). 5. Disconnect the intermediate cable from the LH rear cable at the cable equalizer. 6. Disconnect the front of the LH rear cable conduit at the frame bracket. 7. Disconnect the LH parking brake cable from the parking brake lever and remove the cable. 8. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Removal and Installation 1. Release the parking brake cable tension. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6167 2. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Remove the 2 wire form bolts. ^ To install, tighten to 15 Nm (11 lb-ft). 4. Remove the 2 parking brake cable bracket-to-crossmember bolts. ^ To install, tighten to 15 Nm (11 lb-ft). 5. Disconnect the intermediate parking brake cable from the RH rear parking brake cable at the parking brake cable equalizer. 6. Disconnect the front of the RH parking brake cable conduit at the frame bracket. 7. Disconnect the RH parking brake cable from the parking brake lever and remove the parking brake cable. 8. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Parking Brake Cable - Front Parking Brake Cable - Front Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6168 Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6169 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the screw and the hood latch release handle. 3. Remove the pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch release cable assembly screw and position the release cable assembly aside. 5. Release the tension on the parking brake cable. 6. Remove the 2 screws and the instrument panel steering column cover. 7. Remove the 2 parking brake release handle bolts from the bracket. ^ To install, tighten to 3 Nm (27 lb-in). 8. Disconnect the parking brake switch electrical connector. 9. Remove the wiring harness bracket screw and position the harness and bracket aside. 10. Remove the 3 bolts from the parking brake control. ^ To install, tighten to 20 Nm (15 lb-ft). 11. Position the carpet aside. 12. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to be removed. Disconnect the front parking brake cables from the parking brake control. 13. Disconnect the front parking brake cable conduit from the parking brake control. 14. Disconnect the front parking brake cable from the bracket and remove the cable. 15. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Parking Brake Cable - Intermediate Parking Brake Cable - Intermediate NOTE: The equalizer is integral to the intermediate cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 6170 Removal and Installation 1. Release the tension on the parking brake cable. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the intermediate parking brake cable from the front cable at the cable connector clip. 4. Disconnect the LH and RH rear parking brake cables from the intermediate parking brake cable at the equalizer. 5. Remove the intermediate parking brake cable. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 6174 Removal and Installation 1. Remove the screw and the hood latch release handle. 2. Remove the pin-type retainer and the LH A-pillar lower trim panel. 3. Remove the hood latch release cable assembly screw and position the release cable assembly aside. 4. Release the tension on the parking brake cable. 5. Remove the 2 screws and the instrument panel steering column cover. 6. Remove the 2 parking brake release handle bolts from the bracket. ^ To install, tighten to 3 Nm (27 lb-in). 7. Disconnect the parking brake switch electrical connector. 8. Remove the wiring harness bracket screw and position the harness and bracket aside. 9. Remove the 3 bolts from the parking brake control. ^ To install, tighten to 20 Nm (15 lb-ft). 10. Position the carpet aside and position the cable conduit grommet up through the floor. 11. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to be removed. Disconnect the front parking brake cable and conduit from the parking brake control. 12. Remove the parking brake control from the vehicle. 13. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments Parking Brake Shoe Adjustment 1. NOTE: Make sure the parking brake is fully released. Using the release handle, release the parking brake control. 2. Remove the rear brake disc. 3. Using the special tool, measure the inside diameter of the drum portion of the rear brake disc and set the locking screw. ^ Record the measurement. 4. Place the special tool over the widest diameter of the parking brake shoes. 5. Adjust the parking brake shoe clearance to 0.54 mm (0.021 in) less than the inside diameter of the drum portion of the rear brake disc. ^ Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc clearance. 6. Install the rear brake disc. 7. Test the parking brake for normal operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6178 Parking Brake Shoe: Service and Repair Parking Brake Shoes Removal NOTE: A parking brake shoe kit contains the linings required for both the LH and RH side. 1. NOTE: Make sure the parking brake control is fully released. Release the tension on the parking brake cable. For additional information, refer to Parking Brake Cable Tension Release. 2. Remove the rear brake disc. 3. Remove the parking brake shoe adjusting screw. 4. Remove the parking brake shoe adjusting screw spring. 5. Remove the 2 parking brake shoe hold-down springs and pins. 6. Remove the parking brake shoe retracting spring and the parking brake shoes. Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6179 1. Position the parking brake shoes and attach the retracting spring. 2. Install the 2 parking brake shoe hold-down pins and springs. 3. Install the parking brake shoe adjusting screw spring. 4. NOTE: Completely retract the parking brake adjusting screw before installation. Install the brake shoe adjusting screw. 5. Adjust the parking brake shoe. 6. Reload the tension on the parking brake cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 6183 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 6184 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6189 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6190 C149 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6194 Vacuum Brake Booster: Description and Operation Brake Booster The power brake actuation system consists of the following components: ^ Brake booster assembly ^ Brake booster vacuum fitting Pedal pressure is amplified by the brake booster. The brake booster uses engine vacuum from the intake manifold. The low pressure in the intake manifold is applied to a rubber diaphragm on the vacuum side of the brake booster chamber, which then pulls the piston rod in when the brakes are applied to supply a power assist. The piston rod is connected to the brake pedal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6195 Vacuum Brake Booster: Testing and Inspection Brake Booster 1. Disconnect the check valve from the brake booster. 2. Apply the parking brake, start the engine and place the transmission in NEUTRAL. 3. Verify that manifold vacuum is available at the check valve with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, connect the check valve and continue with Step 5. ^ If manifold vacuum is not available, continue with Step 4. 4. Disconnect the check valve from the vacuum hose and verify that manifold vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, install a new check valve and continue with Step 5. ^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and diagnose the no vacuum condition. 5. Apply the brake pedal several times to exhaust all vacuum from the system. 6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves downward after the engine starts. ^ If the brake pedal moves, the brake booster is operating correctly. ^ If the brake pedal does not move, install a new brake booster. 7. 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 brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6196 Vacuum Brake Booster: Service and Repair Brake Booster Removal and Installation 1. CAUTION: The brake booster check valve must be disconnected from the brake booster prior to removing the master cylinder or the master cylinder seal may be drawn into the brake booster. Disconnect the brake booster check valve from the brake booster to deplete the residual vacuum in the brake booster. 2. Remove the brake master cylinder. 3. NOTE: When the repair is complete, make sure that the brake booster solenoid electrical connector is connected, or use of the vehicle with key-on or vehicle running will result in DTCs being set. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6197 Disconnect the brake booster solenoid electrical connector. 4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster push rod clevis locking pin is removed, a new booster push rod clevis locking pin should be used. Remove the booster push rod clevis locking pin and discard. 5. Disconnect the brake booster rod from the brake pedal and position aside. 6. NOTE: Use new nuts when installing the brake booster. Remove the 4 brake booster nuts and the booster. ^ To install, tighten to 22 Nm (16 lb-ft). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 brake booster check valve is to allow manifold vacuum to enter the brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. 1. Disconnect the vacuum booster hose from the check valve. 2. Apply the parking brake, start the engine and place the transmission in NEUTRAL. 3. Verify that manifold vacuum is available at the check valve end of the vacuum hose with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, connect the vacuum hose to the check valve and continue this test. ^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and diagnose the no vacuum condition. 4. Connect the vacuum hose to the check valve and run the engine for at least 10 seconds. 5. Operate the brake pedal to check for power assist. ^ If power assist is present, continue with this test. ^ If power assist is not present, refer to Brake Booster Component Test. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Booster 6. NOTE: Do not remove the brake booster check valve from the brake booster in this step. Stop the engine and disconnect the vacuum booster hose from the brake booster check valve. 7. Apply the brake and verify that there is enough vacuum retained in the brake booster for at least one power-assisted brake application. ^ If there is enough vacuum for at least one power-assisted brake application, the check valve is functioning correctly. ^ If there is not enough vacuum for at least one power-assisted brake application, continue with this test. 8. Inspect the brake booster for any signs of damage that could cause a leak. ^ If any damage is found, install a new brake booster and repeat this test. ^ If no damage is found, install a new check valve. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 6205 C239 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6210 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6211 Electronic Brake Control Module: Diagrams C155 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6212 C155 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6213 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Programmable Module Installation in Information Bus (Module Configuration). 1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 lb-in). 3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the hydraulic control unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 6217 C239 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6222 C3073 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6223 ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 6224 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6228 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6229 C149 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6233 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6234 C124 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 6238 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 6242 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 6243 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6250 C280 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6251 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 lb-in). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6252 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6257 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6258 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6259 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6260 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6261 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6262 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6263 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6266 C160 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6267 C440 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6268 C426 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6271 ^ To install, tighten to 17 Nm (13 lb-ft). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6272 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear 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 wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Page 6276 Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6286 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6287 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 6293 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6296 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6297 Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6298 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair BATTERY CABLES LH Engine Connections (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 6303 LH Engine Connections (Part 2) RH Engine Connections Removal and Installation 1. Disconnect the battery. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the nut and position the battery cable body ground terminal aside. - To install, tighten to 9 Nm (80 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 6304 4. Disconnect the battery cable electrical connector. 5. Remove the 2 battery cable locators from the battery tray. 6. Remove the battery junction box (BJB) terminal nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Position the generator harness terminal aside. 8. Position the BJB terminal aside. 9. Remove the 2 nuts and position the battery cable bracket aside. - To install, tighten to 20 Nm (15 lb-ft). 10. Remove the nut and position the power steering (P/S) line bracket aside. - To install, tighten to 12 Nm (9 lb-ft). 11. Remove the nut and position the battery cable engine front cover bracket aside. - To install, tighten to 10 Nm (89 lb-in). 12. Disconnect the A/C compressor electrical connector. 13. Remove the A/C compressor electrical connector harness locator. 14. Remove the bolt and position the battery cable right engine mount bracket aside. - To install, tighten to 20 Nm (15 lb-ft). 15. Remove the starter solenoid terminals protective cap. 16. Remove the nut and position the starter solenoid positive cable terminal aside. - To install, tighten to 12 Nm (9 lb-ft). 17. Remove the nut and position the starter solenoid wire cable terminal aside. - To install, tighten to 6 Nm (53 lb-in). 18. Remove the nut and position the battery cable engine ground terminal aside. - To install, tighten to 25 Nm (18 lb-ft). 19. Remove the battery cable. 20. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Generator Generator amps............................................................................82/135 amps (max) (R) 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Voltage......................................... .............................................................................................................................................................. ..................12 volts Generator Load at 2,000 rpm................................................................................................................................ ....................................................................82 amps No Load at 2,000 rpm........................................ .......................................................................................................................between 13.2 and 15.5 volts Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 6310 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Alternator: Connector Views C102A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 C102B C102C C1104A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 C1104B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6329 Alternator: Application and ID Item....................................................................................................................................................... ..............................................................Specification Generator Generator pulley ratio........................................................................................................................... ..........................................................................2.72:1 Rating.......................................................................................................82/135 amp (max) (R) 1,800-6,000 generator rpm, approx. 500-2,000 engine rpm Voltage regulator type............................ ..............................................................................................................................Electronic internal with generator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6330 Alternator: Description and Operation GENERATOR The charging system consists of the following components: - Generator - Integral voltage regulator 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6331 Alternator: Service and Repair GENERATOR Part 1 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6332 Removal and Installation 1. Disconnect the battery. 2. Remove the throttle body (TB). 3. Rotate the front end accessory drive (FEAD) belt tensioner clockwise and position the FEAD aside. 4. Remove the 3 harness locators from the generator bracket. 5. Remove the 4 bolts and the generator bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Loosen the 2 bolts and position the generator aside. - To install, tighten to 25 Nm (18 lb-ft). 7. Disconnect the generator electrical connector. 8. Position the protective cover aside, remove and discard the nut and position the generator B+ terminal aside. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the generator. 10. If necessary, remove the nut and the generator pulley. - To install, tighten to 109 Nm (80 lb-ft). 11. To install, reverse the removal procedure. - Install a new generator B+ terminal nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6341 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6342 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Normal engine cranking speed............................................................................................................. ................................................................140-220 rpm Starter motor no load current draw................. ........................................................................................................................................................6080 amps Starter motor normal load current draw................................................................................. .............................................................................130-220 amps Starter motor maximum load current draw.......................................................................................................................................... ......................800 amps Starter motor minimum stall torque (at 5 volts)........................................................................................................................................14.7 Nm (10.8 lb-ft) Starter circuit maximum voltage drop (engine normal operating temperature).............................................................................................................0.5 volt Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 6347 Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6348 Starter Motor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6349 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6350 Starter Motor: Diagrams C197A C197B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6351 Starter Motor: Service and Repair STARTER MOTOR Removal and Installation WARNING: Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the starter solenoid terminal cover. 4. Remove the B terminal nut and disconnect the cable. - To install, tighten to 12 Nm (9 lb-ft). 5. Remove the S terminal nut and disconnect the cable. - To install, tighten to 6 Nm (53 lb-in). 6. Remove the nut and disconnect the ground cable from the stud bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Remove the bolts, the stud bolt and the starter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6352 - To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. - Tighten the upper bolt before tightening the lower fasteners. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay > Page 6357 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6360 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6361 Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6362 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear C474 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6368 C3063 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6369 C3064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6370 C3323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point PICKUP BED POWER POINT Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. 2. Disconnect the power point receptacle electrical connector and remove the power point receptacle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6373 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6374 Auxiliary Power Outlet: Service and Repair Power Point POWER POINT Special Tool(s) Special Tool(s) Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the special tool in one of the power point socket slots. 3. Position the special tool so that it engages in the adjacent slot. 4. Using the special tool, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6375 Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 C174 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6380 C194 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6381 C1196 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6386 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6387 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6388 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6389 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6390 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6391 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6392 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6393 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6394 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6395 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6396 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6414 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6415 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6416 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6417 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6418 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6419 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6420 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6421 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6422 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6423 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6424 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6429 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6430 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6431 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6432 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6433 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6434 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6435 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6436 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6437 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6438 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6439 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Fuse Block: Connector Views C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6464 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6465 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6466 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6467 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6468 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6469 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6470 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6471 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6472 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6473 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6474 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 Multiple Junction Connector: Diagrams C110-C422 C110 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6485 C133 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6486 C134 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6487 C139 C140 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6488 C146 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6489 C192 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6490 C210 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6491 C210 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6492 C211 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6493 C212 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6494 C214 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6495 C214 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6496 C215 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6497 C219 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6498 C237 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6499 C248 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6500 C260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6501 C300 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6502 C311 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6503 C311 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6504 C312 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6505 C312 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6506 C317 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6507 C327 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6508 C340 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6509 C313 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6510 C314 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6511 C315 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6512 C316 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6513 C328 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6514 C328 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6515 C339 C405 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6516 C406 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6517 C408 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6518 C410 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6519 C411 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6520 C421 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6521 C422 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6522 Multiple Junction Connector: Diagrams C423-C4004 C423 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6523 C431 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6524 C432 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6525 C438 C465 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6526 C494 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6527 C495 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6528 C510 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6529 C511 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6530 C610 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6531 C700 C800 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6532 C913 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6533 C925 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6534 C3007 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6535 C3047 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6536 C3049 C3050 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6537 C3052 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6538 C3053 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6539 C3134 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6540 C3135 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6541 C3135 (Part 2) C3138 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6542 C4000 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6543 C4004 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6547 Part 2 Removal CAUTION: - If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6548 9. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 10. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11 If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower, right SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: - When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. - When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry Transmitter Programming Download the SJB configuration information from the scan tool into the new SJB. 15. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6549 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear the DTC C2780. Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6563 Part 2 Removal CAUTION: - If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6564 9. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 10. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11 If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower, right SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: - When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. - When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry Transmitter Programming Download the SJB configuration information from the scan tool into the new SJB. 15. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6565 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear the DTC C2780. Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6573 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6574 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6575 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6576 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6577 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6578 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6579 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6580 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6581 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6582 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6583 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6586 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6587 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6588 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6589 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6590 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6591 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6594 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6595 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6596 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6597 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6598 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6599 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6600 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6601 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6602 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6603 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6604 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6609 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6610 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6611 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6612 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6613 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6614 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6615 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6616 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6617 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6618 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6619 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6622 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6623 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6624 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6625 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6626 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6627 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6630 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6631 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6632 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6633 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6634 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6635 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6636 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6637 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6638 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6639 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6640 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear C474 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6646 C3063 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6647 C3064 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 6648 C3323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point PICKUP BED POWER POINT Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. 2. Disconnect the power point receptacle electrical connector and remove the power point receptacle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6651 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6652 Auxiliary Power Outlet: Service and Repair Power Point POWER POINT Special Tool(s) Special Tool(s) Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the special tool in one of the power point socket slots. 3. Position the special tool so that it engages in the adjacent slot. 4. Using the special tool, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 6653 Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 C174 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6658 C194 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6659 C1196 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6664 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6665 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6666 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6667 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6668 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6669 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6670 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6671 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6672 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6673 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6674 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6692 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6693 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6694 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6695 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6696 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6697 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6698 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6699 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6700 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6701 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6702 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6707 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6708 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6709 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6710 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6711 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6712 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6713 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6714 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6715 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6716 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6717 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Fuse Block: Connector Views C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6742 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6743 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6744 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6745 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6746 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6747 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6748 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6749 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6750 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6751 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6752 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 Multiple Junction Connector: Diagrams C110-C422 C110 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6763 C133 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6764 C134 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6765 C139 C140 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6766 C146 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6767 C192 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6768 C210 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6769 C210 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6770 C211 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6771 C212 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6772 C214 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6773 C214 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6774 C215 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6775 C219 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6776 C237 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6777 C248 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6778 C260 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6779 C300 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6780 C311 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6781 C311 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6782 C312 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6783 C312 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6784 C317 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6785 C327 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6786 C340 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6787 C313 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6788 C314 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6789 C315 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6790 C316 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6791 C328 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6792 C328 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6793 C339 C405 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6794 C406 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6795 C408 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6796 C410 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6797 C411 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6798 C421 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6799 C422 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6800 Multiple Junction Connector: Diagrams C423-C4004 C423 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6801 C431 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6802 C432 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6803 C438 C465 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6804 C494 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6805 C495 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6806 C510 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6807 C511 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6808 C610 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6809 C700 C800 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6810 C913 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6811 C925 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6812 C3007 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6813 C3047 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6814 C3049 C3050 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6815 C3052 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6816 C3053 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6817 C3134 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6818 C3135 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6819 C3135 (Part 2) C3138 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6820 C4000 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C422 > Page 6821 C4004 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6825 Part 2 Removal CAUTION: - If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6826 9. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 10. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11 If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower, right SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: - When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. - When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry Transmitter Programming Download the SJB configuration information from the scan tool into the new SJB. 15. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6827 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear the DTC C2780. Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6841 Part 2 Removal CAUTION: - If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. - The tire pressure monitoring system (TPMS) functionality is integral to the SJB. - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6842 9. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 10. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11 If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower, right SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: - When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. - When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry Transmitter Programming Download the SJB configuration information from the scan tool into the new SJB. 15. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6843 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear the DTC C2780. Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6851 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6852 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6853 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6854 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6855 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6856 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6857 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6858 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6859 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6860 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6861 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6864 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6865 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6866 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6867 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6868 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6869 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6872 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6873 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6874 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6875 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6876 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6877 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6878 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6879 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6880 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6881 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 / Smart Junction Box (SJB) > Page 6882 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6887 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6888 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6889 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6890 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6891 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6892 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6893 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6894 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6895 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6896 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6897 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6900 Relay Box: Diagrams Smart Junction Box (SJB) C2280A (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6901 C2280A (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6902 C2280B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6903 C2280C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6904 C2280D Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6905 C2280E Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6908 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6909 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6910 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6911 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6912 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6913 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6914 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6915 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6916 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6917 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6918 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6924 Alignment: Specifications General Specifications General Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6925 Alignment: Specifications Torque Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6926 Alignment: Description and Operation Suspension System The front camber and caster are adjusted by loosening the upper control arm bolts which will allow the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole. Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by replacing the upper arm inboard flagnut with a non-flagnut to allow the arm to be adjusted in the slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6927 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow. Wander 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 and 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 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1. Using alignment equipment and the manufacturer's instructions, measure the front caster and camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the following chart. ^ When making adjustments that require moving both the front and the rear of the upper arm, move both ends of the arm equally. 3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber settings are not disturbed while tightening the bolt(s). Tighten the upper arm bolt(s) to 150 Nm (111 lb-ft). 4. NOTE: caster split adjustment can be made by loosening the LF lower arm rearward nut and adjusting the rear of the LF lower arm. Remove and discard the LF lower control arm rearward nut. 5. NOTE: Do not fully tighten the nut and bolt at this time. Install a new LF lower arm rearward nut. 6. Position the LF lower arm until the caster split is within specification. 7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are not disturbed while tightening the nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6930 Tighten the LF lower arm rearward nut to 200 Nm (148 lb-ft). 8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6931 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the lower arm inboard bolt. ^ Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement A). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6932 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm until the scriber point is located in the center of the shock absorber lower bolt. ^ Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement B). 5. Subtract measurement B from measurement A to obtain the front ride height. ^ Refer to Specifications. Rear Ride Height Measurement Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6933 Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt (measurement A). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement B). 3. Subtract measurement B from measurement A to obtain the rear ride height. ^ Refer to Specifications. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6934 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is rotated. Remove the clamps. 5. Loosen the tie-rod jam nuts. 6. Rotate the front wheel inner tie rods until the toe setting is within specification. 7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the steering gear bellows can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the nuts. Tighten the tie-rod jam nuts to 70 Nm (52 lb-ft). 8. Install the clamps. 9. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6935 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard nut. 5. Rotate the rear toe link cam bolt until the toe setting is within specification. 6. NOTE: Make sure the toe settings are not disturbed while tightening the nut. While holding the adjustment cam bolt, tighten the toe link inboard nut. ^ Tighten to 275 Nm (202 lb-ft). 7. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6936 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear 1. Index-mark the upper arm inboard bolt to the frame. 2. NOTE: The upper arm inboard flagnut must be removed and replaced with a non-flagnut to allow for the adjustment of the arm in the frame slot. Remove and discard the upper arm inboard bolt and flagnut. ^ Install a new non-flagnut. 3. Using alignment equipment and the manufacturer's instructions, measure the rear camber. 4. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber. NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber. NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the upper arm outward. Position the upper arm until the camber setting is within specification. 5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6937 Tighten the upper arm inboard nut to 250 Nm (185 lb-ft). 6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6943 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6944 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 6948 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 6949 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6954 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6955 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6961 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6962 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6965 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6966 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6967 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6968 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6969 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 6970 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6975 Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6976 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 5. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 6. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Disconnect the wheel speed sensor harness pin-type retainers. 8. Disconnect the wheel speed sensor electrical connector. 9. Remove and discard the tie-rod end nut. ^ To install, tighten to 103 Nm (76 lb-ft). 10. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod boot while installing the special tool. Using the special tool, separate the tie-rod end from the wheel knuckle. 11. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 12. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. 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. 13. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 lb-ft). 14. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6977 Using the special tool, separate the upper ball joint and remove the wheel knuckle. 15. To install, reverse the removal procedure. ^ Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure may result. The condition may occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power steering purge procedure must be carried out prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the power steering pump reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. Refer to the appropriate procedure. 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(R), apply the brake pedal twice. 7. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 8. Stop the engine. 9. Release the vacuum and remove the vacuum pump. 10. NOTE: 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 an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 14. Stop the engine, release the vacuum and remove the vacuum pump. 15. NOTE: Do not overfill the reservoir. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6982 Fill the reservoir as needed and install the reservoir cap. 16. Visually inspect the power steering system for leaks. 17. NOTE: Do not overfill the reservoir. Fill the reservoir as needed and visually inspect the power steering system for leaks. 18. Install the reservoir cap. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Ford Part Name ................................................................................................................................... ................................ Motorcraft MERCON V ATF Ford Part Number ................................................. ............................................................................................................................................. XT-5-QM Ford Specification ................................................................................................................................ ......................................................... MERCON V Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 6986 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. Refer to Inspection and Verification. 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 an extended amount of time. Damage to the power steering pump may 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. 10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may 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. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6990 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6991 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the power steering fluid cooler clamp and disconnect the fluid cooler from the fluid reservoir. 3. Remove the LH front splash shield screws, pin-type retainers and the splash shield. 4. Remove the lower radiator air deflector pushpins and the air deflector. 5. Remove the 2 power steering fluid cooler hose braces. 6. Remove the power steering fluid cooler hose bracket bolt. ^ To install, tighten to 18 Nm (13 lb-ft). 7. Remove the steering line clamp plate nut. ^ To install, tighten to 25 Nm (18 lb-ft). 8. Rotate the steering line clamp plate and disconnect the power steering fluid cooler from the steering gear. ^ Discard the O-ring seal. 9. Remove the power steering fluid cooler. 10. NOTE: New O-ring seals must be installed whenever the power steering pressure and fluid cooler line is disconnected from the steering gear. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 6995 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. Using a suitable suction device, remove the power steering fluid from the reservoir. 2. Remove the power steering fluid reservoir bolt. ^ To install, tighten to 9 Nm (80 lb-inch). 3. Release the power steering pump supply hose clamp and disconnect the hose. 4. Release the power steering fluid cooler hose clamp and disconnect the hose. 5. Remove the power steering fluid reservoir. 6. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 6999 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the power steering fluid cooler from the steering gear. ^ Discard the O-ring seal. 5. Disconnect the pressure line from the steering gear. ^ Discard the O-ring seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 7000 6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). 7. Remove the pressure line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting. ^ Remove and discard the Teflon(R) seal. 9. Remove the pressure line. Installation 1. NOTE: new Teflon(R) seal must be installed. Using the special tool, install a new Teflon(R) seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 lb-ft). 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). ^ Tighten to 11 Nm (8 lb-ft). 4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are disconnected from the steering gear. Install a new O-ring seal and position the pressure line to the steering gear. 5. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 12 Nm (9 lb-ft). 6. Install a new O-ring seal and position the power steering fluid cooler to the steering gear. Rotate the steering line clamp plate into position. 7. Install the steering line clamp plate nut. ^ Tighten to 25 Nm (18 lb-ft). 8. Install the power steering pump pulley. 9. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 - 4.6L Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7005 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. Using a suitable suction device, remove the power steering fluid from the reservoir. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the power steering pump pulley. 4. Remove the pressure line bracket-to-engine nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7006 5. Compress the clamp and disconnect the power steering pump supply hose. 6. Disconnect the pressure line-to-pump fitting. ^ Remove and discard the Teflon(R) seal. 7. Remove the 2 engine wiring bracket nuts and position the wiring harness and ground cable aside. 8. Remove the 3 bolts and the power steering pump. Installation 1. NOTE: new Teflon(R) seal must be installed. Using the special tool, install a new Teflon(R) seal on the pressure line-to-pump fitting. 2. Position the power steering pump and install the 3 bolts. ^ To install, tighten to 20 Nm (15 lb-ft). 3. Position the ground cable and engine wiring bracket. Install the 2 nuts. ^ Tighten to 20 Nm (15 lb-ft). 4. Connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 lb-ft). 5. Connect the power steering pump supply hose. 6. Install the pressure line bracket-to-engine nut. ^ Tighten to 11 Nm (8 lb-ft). 7. Install the power steering pump pulley. 8. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7007 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley - 4.6L Removal 1. Remove the engine air cleaner outlet pipe. 2. Rotate the tensioner and remove the engine accessory drive belt from the power steering pump pulley. 3. Using the special tool, remove the pulley. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7008 Installation 1. CAUTION: Do not install a power steering pump pulley that has been removed and installed twice or pulley failure and/or pump damage may occur. Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, discard the pulley and install a new one. If there is 1 paint mark or no paint marks, use a paint pencil to mark the web area of the pulley near the hub. Using the special tool, install the pulley. 2. Rotate the tensioner and install the engine accessory drive belt on the power steering pump pulley. 3. Install the engine air cleaner outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7013 C121 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7014 Power Steering Pressure Switch: Description and Operation 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7018 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7019 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 7023 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 7024 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7030 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7031 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7032 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7033 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7034 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7035 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7036 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7037 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7038 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7039 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7040 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7041 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7042 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Adaptive Collapsible Steering Column > Component Information > Service and Repair Adaptive Collapsible Steering Column: Service and Repair DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury. 1. Depower the SRS. 2. NOTE: It may be necessary to lower or remove the deployable steering column from the instrument panel to access the deployable steering column electrical connector. Access the deployable steering column electrical connector. 3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering column. Cut each of the deployable steering column wires, leaving at least 4 inches to work with. 4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5. Make a jumper harness to deploy the deployable steering column. - Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire. - At one end of the jumper harness, connect the wires together. 6. Using the end of the jumper harness that the wires are not connected together, attach each wire of the jumper harness to each wire of the deployable steering column. Use tape or other insulating material to make sure that the leads do not make contact with each other. 7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of the jumper harness from each other. 9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column. 11. Dispose of the deployed steering column in the same manner as any other part to be scrapped. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Gear Valve Test Steering Gear: Testing and Inspection Steering Gear Valve Test Steering Gear Valve Test 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. ^ If the vehicle does not pull with the engine OFF, repair or install a new steering gear. 2. If the vehicle pulls with the engine OFF, switch the right side front wheel to the left side of the vehicle and the left side front wheel to the right side of the vehicle. 3. If the vehicle pulls to the opposite side, switch the front wheels with the rear wheels keeping them on the same side of the vehicle. 4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Gear Valve Test > Page 7050 Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1,200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may 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. Refer to Power Steering System Purging. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7051 Steering Gear: Service and Repair Steering Gear Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7052 Removal and Installation All vehicles CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. CAUTION: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the lower shaft has rotated, the clockspring must be removed and recentered. Hold the steering wheel in the straight-ahead position using a suitable device. 2. Remove the front tires and wheels. 3. If equipped, remove the 2 bolts, pin-type retainer and the oil shield. ^ To install, tighten to 15 Nm (11 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7053 4. NOTE: Install a new lower steering column shaft-to-steering gear bolt. Remove and discard the lower steering column shaft-to-steering gear bolt. ^ To install, tighten to 48 Nm (35 lb-ft). 5. Disconnect the lower steering column shaft from the steering gear. 6. Remove the steering line clamp plate nut. ^ To install, tighten to 25 Nm (18 lb-ft). 7. Rotate the steering line clamp plate and disconnect the power steering pressure line and fluid cooler. 8. NOTE: New O-rings must be installed whenever the power steering line and fluid cooler are disconnected from the steering gear. Remove and discard the 2 O-rings. 9. NOTE: New tie-rod end nuts must be installed. Remove and discard the 2 tie-rod end nuts. ^ To install, tighten to 103 Nm (76 lb-ft). 10. CAUTION: Do not damage the tie-rod end boot when installing the special tool. Using the special tool, separate the 2 tie-rod ends from the wheel knuckle. 11. Remove the 2 steering gear-to-crossmember nuts and bolts. ^ To install, tighten to 350 Nm (258 lb-ft). Four wheel drive (4WD) vehicles NOTE: On four wheel drive (4WD) vehicles, the following steps (LH lower arm only) must be carried out to provide clearance to remove the steering gear. 12. Remove the shock absorber lower bolt and flagnut. ^ Discard the flagnut. ^ To install, tighten to 350 Nm (258 lb-ft). 13. CAUTION: Do not tighten the LH lower arm nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load or bushing damage may occur. NOTE: It is not necessary to disconnect the LH lower ball joint. Remove and discard the lower arm forward bolt and nut and the lower arm rearward flag bolt and nut. ^ To install the lower arm forward bolt, tighten to 400 Nm (296 lb-ft). ^ To install the lower arm rearward flag bolt and nut, tighten to 200 Nm (148 lb-ft). 14. Remove the stabilizer bar link nut and the link. ^ Discard the stabilizer bar link nut. ^ To install, tighten to 35 Nm (26 lb-ft). All vehicles 15. Remove the steering gear from the LH side of the vehicle. 16. If a new steering gear is being installed, remove the 4 steering gear bushings and the 2 nuts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 7054 17. CAUTION: On four wheel drive (4WD) vehicles, do not tighten the LH lower arm nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load bushing damage may occur. To install, reverse the removal procedure. ^ Install 2 new O-ring seals. ^ Fill the power steering system. ^ Check and, if necessary, set the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Column Shaft - Upper Steering Shaft: Service and Repair Steering Column Shaft - Upper Steering Column Shaft - Upper Steering Column Shaft - Upper Removal and Installation 1. CAUTION: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. 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. 2. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the upper steering column shaft-to-steering column bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 3. Remove the 3 upper steering column shaft dash seal bolts. ^ To install, tighten to 12 Nm (9 lb-ft). 4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. ^ To install, tighten to 47 Nm (35 lb-ft). 5. Remove the upper steering column shaft. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Column Shaft - Upper > Page 7059 Steering Shaft: Service and Repair Steering Column Shaft - Lower Steering Column Shaft - Lower Steering Column Shaft - Lower Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not allow the steering column shaft to rotate while the steering column shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Place the steering wheel and the front wheels in the straight-ahead position. ^ Turn the ignition switch to the OFF position and remove the key. 3. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. ^ To install, tighten to 47 Nm (35 lb-ft). 4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-steering gear bolt. ^ To install, tighten to 47 Nm (35 lb-ft). 5. Remove the lower steering column shaft. 6. Inspect the lower steering column shaft for boot damage or separation from the shaft tube. ^ If damage or separation of the lower steering column shaft is evident, install a new lower steering column shaft. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 7063 C203 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 7064 Steering Wheel: Service and Repair Steering Wheel Steering Wheel Removal and Installation 1. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position. 2. Remove the driver air bag module. 3. Disconnect the steering wheel switches electrical connector. 4. NOTE: A new bolt must be installed. Remove the steering wheel bolt and the steering wheel. ^ Discard the bolt. ^ To install, tighten to 40 Nm (30 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7068 Removal CAUTION: The boots and clamps are designed to provide an airtight seal and protect the internal components of the steering gear. If the seal is not airtight the vacuum generated during turning will draw water and contamination into the gear causing damage. Zip ties do not produce an airtight seal and must not be used. CAUTION: The inner ball joint grease is not compatible with water and foreign material trapped in the grease will degrade the life of the joint. CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes can be installed in the correct location. Incorrect venting may lead to internal component damage. 1. Remove the front tire and wheel. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the tie-rod end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7069 4. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate 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 outer bellows boot clamp must be installed. Using the boot clamp pliers, remove and discard the outer bellows boot clamp. 8. NOTE: new inner bellows boot clamp must be installed. Using the boot clamp pliers, remove and discard the inner bellows boot clamp. 9. Remove the steering gear bellows boot. 10. 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. 11. 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 100 Nm (74 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7070 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. NOTE: Make sure the steering gear bellows boot is not twisted and the vent tube (if equipped) is securely inserted into the vent nipple of the steering gear bellows boot. 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. Tighten the tie-rod end jam nut. ^ Tighten to 80 Nm (59 lb-ft). 8. Position the tie-rod end to the wheel knuckle and install a new tie-rod end nut. ^ Tighten to 103 Nm (76 lb-ft). 9. Check and, if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7075 Ball Joint: Testing and Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Refer to Vehicle/Testing and inspection. 2. 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 may 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. 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 may 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7076 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Lower Arm Lower Arm Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7081 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7082 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. Remove the wheel and tire. 3. Remove and discard the lower ball joint nut. 4. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. 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. 5. Remove and discard the stabilizer bar link nut and grommet. 6. Remove the stabilizer bar link. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7083 7. Remove and discard the shock absorber lower bolt and flag nut. 8. Remove and discard the lower arm forward nut and bolt. 9. Remove the lower arm rearward nut and bolt and the lower control arm. ^ Discard the nut and bolt. Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). This will prevent incorrect clamp load and bushing damage. 1. NOTE: Do not tighten the bolt at this time. Position the lower arm and install the lower arm rearward bolt and nut. 2. NOTE: Do not tighten the bolt at this time. Install the lower arm forward bolt and nut. 3. NOTE: Do not tighten the bolt at this time. Install the shock absorber lower bolt and flag nut. 4. Install the stabilizer bar link. ^ Tighten the nut to 35 Nm (26 lb-ft). 5. Connect the lower ball joint to the wheel knuckle and install the lower ball joint nut. ^ Tighten to 150 Nm (111 lb-ft). 6. Using a suitable jack, raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). 7. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 8. Tighten the lower arm forward nut to 400 Nm (296 lb-ft). 9. Tighten the lower arm rearward nut to 200 Nm (148 lb-ft). 10. Install the wheel and tire. 11. Check and if necessary, align the front end. Upper Arm Upper Arm Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7084 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. Remove the wheel and tire. 3. Using a suitable jack support the lower control arm near the lower ball joint. 4. Remove and discard the upper ball joint nut. 5. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7085 CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 6. Using a plastic tie strap, support the suspension at the wheel knuckle. 7. Remove and discard the 2 upper arm bolts and flag nuts and the upper arm. Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). This will prevent incorrect clamp load and bushing damage. 1. NOTE: Do not tighten the bolt at this time. Position the upper arm and install the 2 upper arm bolts and flag nuts. 2. Remove the plastic tie strap. 3. Connect the upper ball joint to the wheel knuckle and install the upper ball joint nut. ^ Tighten to 55 Nm (41 lb-ft). 4. Using a suitable jack, raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). 5. Tighten the 2 upper arm bolts to 150 Nm (111 lb-ft). 6. Install the wheel and tire. 7. Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7086 Control Arm: Service and Repair Rear Upper Arm Upper Arm Upper Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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, or incorrect clamp load and component damage may occur. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7087 2. Remove the wheel and tire. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Remove and discard the upper arm outboard nut and bolt. 5. NOTE: The inboard nut that is installed at the assembly plant is a flagnut. This flagnut is used to set and maintain the rear camber settings. Discard the flagnut and install a non-flagnut to allow the rear camber to be adjusted. Remove and discard the upper arm inboard bolt and flagnut and remove the upper arm. Installation 1. Position the upper arm and install a new inboard bolt and non-flagnut. ^ Tighten to 250 Nm (185 lb-ft). 2. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage can occur. Install a new outboard bolt and nut with the bolt head toward the front of the vehicle. ^ Tighten to 225 Nm (166 lb-ft). 3. Lower the suspension and remove the jack. 4. Check and, if necessary, align the rear end. Lower Arm Lower Arm Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7088 Lower Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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 or incorrect clamp load and component damage may occur. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7089 2. Remove the wheel and tire. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Remove and discard the lower arm outboard bolt and flagnut. 5. Remove the stabilizer bar link nut and grommet and the stabilizer bar link. ^ Discard the nut and grommet. 6. Lower the suspension and remove the jack. 7. Remove and discard the shock absorber lower nut and bolt. 8. Remove and discard the lower arm inboard nut and bolt and remove the lower arm. Installation 1. NOTE: Do not tighten the lower arm inboard nut at this time. Position the lower arm and install a new lower arm inboard bolt and nut. 2. NOTE: Do not tighten the shock absorber lower nut at this time. Position the lower arm and install a new shock absorber lower bolt and nut. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Install the stabilizer link and a new nut and grommet. ^ Tighten to 30 Nm (22 lb-ft). 5. Install a new lower arm outboard bolt and flagnut. ^ Tighten the bolt to 275 Nm (203 lb-ft). 6. Tighten the lower arm inboard bolt to 250 Nm (185 lb-ft). 7. Tighten the shock absorber lower bolt to 275 Nm (203 lb-ft). 8. Lower the suspension and remove the jack. 9. Install the wheel and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Cross-Member: Service and Repair Transmission Support Crossmember Transmission Support Crossmember Transmission Support Crossmember Removal and Installation 1. With the vehicle in NEUTRAL, position it on hoist. 2. Remove the 4 transfer case skid plate bolts and remove the transfer case skid plate. - To install, tighten to 15 Nm (11 lb-ft). 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 7095 - To install, tighten to 18 Nm (13 lb-ft). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (13 lb-ft). 5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove the 6 transmission crossmember lower bolts. - To install, tighten to 80 Nm (59 lb-ft). 8. NOTE: Tighten the nut side of the joint. Remove the 2 upper nuts and 2 bolts from the transmission crossmember. - To install, tighten to 143 Nm (105 lb-ft). 9. Remove the transmission crossmember. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 7096 Cross-Member: Service and Repair Crossmember - 1B Crossmember - 1B Crossmember - 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts. - To install, tighten to 103 Nm (76 lb-ft). 4. Remove the 1B crossmember. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7100 Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7101 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 5. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 6. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Disconnect the wheel speed sensor harness pin-type retainers. 8. Disconnect the wheel speed sensor electrical connector. 9. Remove and discard the tie-rod end nut. ^ To install, tighten to 103 Nm (76 lb-ft). 10. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod boot while installing the special tool. Using the special tool, separate the tie-rod end from the wheel knuckle. 11. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 lb-ft). 12. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. 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. 13. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 lb-ft). 14. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7102 Using the special tool, separate the upper ball joint and remove the wheel knuckle. 15. To install, reverse the removal procedure. ^ Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7106 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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 or incorrect clamp load and damage to components may occur. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. If equipped, remove the wheel speed sensor bolt and position the sensor aside. 3. CAUTION: Do not loosen the halfshaft nut and washer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Remove and discard the wheel hub nut. 4. Remove the parking brake shoes. 5. CAUTION: Do not use a hammer to separate the halfshaft from the hub. Damage to the threads and internal constant velocity (CV) joint components may result. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7107 Using the special tool, press the halfshaft from the hub. 6. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 7. Remove and discard the toe link outboard nut and bolt. 8. Remove and discard the upper arm outboard nut and bolt. 9. Remove and discard the lower arm outboard nut and bolt. 10. Remove and discard the 3 wheel knuckle bolts and remove the wheel knuckle. 11. If a new wheel knuckle is being installed, remove the wheel bearing and wheel hub. Installation 1. Position the wheel knuckle and install 3 new wheel knuckle bolts. ^ Tighten to 275 Nm (203 lb-ft). 2. Install a new lower arm outboard bolt and flagnut. ^ Tighten to 275 Nm (203 lb-ft). 3. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage may occur. Install a new upper arm outboard bolt and nut with the bolt head toward the front of the vehicle. ^ Tighten to 225 Nm (166 lb-ft). 4. Position the toe link and install a new toe link outboard bolt and nut. ^ Tighten to 325 Nm (240 lb-ft). 5. Lower the suspension and remove the jack. 6. Install the parking brake shoes. 7. Position the wheel speed sensor and install the bolt. ^ Tighten to 8 Nm (71 lb-inch). 8. Using a suitable halfshaft installer tool, install the halfshaft. 9. NOTE: Have an assistant press the brake pedal to keep the axle from turning. Install a new halfshaft nut and washer. ^ Tighten to 275 Nm (203 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Toe Link Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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 or incorrect clamp load and component damage may occur. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 7111 2. Remove the wheel and tire. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Index-mark the toe link cam bolt to the subframe. 5. Remove the toe link cam adjuster nut, cam adjuster and cam bolt. ^ Discard the nut. 6. Remove and discard the toe link outboard nut and bolt and remove the toe link. Installation 1. Position the toe link and install a new outboard bolt and nut. ^ Tighten to 325 Nm (240 lb-ft). 2. NOTE: Do not tighten the cam adjuster nut at this time. NOTE: The cam adjuster must be installed with the small tooth facing toward the frame bracket. Install the toe link cam bolt, cam adjuster and a new nut. 3. NOTE: Make sure the cam bolt and the adjustment cam are seated between the offsets before tightening the nut. Align the index mark on the cam bolt with the index mark on the subframe and tighten the nut. ^ Tighten to 275 Nm (203 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 7112 4. Lower the suspension and remove the jack. 5. Install the wheel and tire. 6. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7117 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7118 C226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 For additional information, refer to Suspension. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7124 Stabilizer Link: Service and Repair Rear Stabilizer Bar and Link - Explorer Sport Trac Stabilizer Bar and Link - Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7125 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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 or incorrect clamp load and damage to components may occur. 1. Remove both upper arms. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7126 2. NOTE: Removal of the LH shock absorber lower bolt will allow more movement of the wheel knuckle when installing the stabilizer bar. Remove the LH shock absorber lower bolt. 3. Disconnect the evaporative emission (EVAP) canister vent valve electrical connector. 4. Unclip the wiring harness from the frame. 5. Remove the fuel tank filler pipe bracket bolt. 6. Loosen the fuel tank filler pipe hose clamps and disconnect the hose. 7. Remove the stabilizer bar link nut and grommet and the stabilizer bar link. ^ Discard the nut. 8. Remove the wiring harness retainer caps from the stabilizer bar bracket studs. 9. Remove and discard the 4 stabilizer bar bracket nuts. 10. Remove the 2 stabilizer bar brackets and the 2 stabilizer bar bushings. 11. Remove the 4 stabilizer bar bracket studs. ^ For the front studs, push the stud down and slide the stud toward the rear of the vehicle. ^ For the rear studs, push the stud down and slide the stud toward the front of the vehicle. 12. Disconnect the fuel filler pipe tube-to-fuel pressure sensor line quick connect coupling. 13. Unclip the fuel filler pipe tube-to-fuel pressure sensor line from the fuel tank and position aside. 14. CAUTION: When removing the stabilizer bar, care must be taken to avoid damage to the wiring harness, fuel lines, fuel filler tube and body. CAUTION: Extreme care must be exercised when removing and installing the stabilizer bar on vehicles equipped with rear air conditioning (A/C) and/or rear heating, or damage to the A/C lines and rear heater hoses can occur. With the aid of an assistant, remove the stabilizer bar from the LH side of the vehicle. Installation CAUTION: When installing the stabilizer bar, care must be taken to avoid damage to the wiring harness, fuel lines, fuel filler tube and body. CAUTION: Extreme care must be exercised when removing and installing the stabilizer bar on vehicles equipped with rear air-conditioning (A/C) and/or rear heating, or damage to the A/C lines and rear heater hose may occur. 1. With the aid of an assistant, install the stabilizer bar into the LH side of the vehicle. 2. Connect the fuel filler pipe tube-to-fuel sensor line. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7127 3. Connect the fuel filler pipe tube-to-fuel pressure sensor line quick connect coupling. 4. Install the 4 stabilizer bar bracket studs. 5. Install the 2 stabilizer bar bushings and the 2 stabilizer bar brackets. 6. Install the 4 stabilizer bar bracket nuts. ^ Tighten to 48 Nm (35 lb-ft). 7. Install the wiring harness retaining caps onto the stabilizer bar studs. 8. Use the jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 of the Upper Arm procedure. 9. Install the stabilizer bar link, the new link nut and the grommet. ^ Tighten to 30 Nm (22 lb-ft). 10. Connect the fuel tank filler hose. ^ Tighten the 2 filler pipe hose clamps to 3 Nm (27 lb-inch). 11. Install the fuel tank filler pipe bracket bolt. ^ Tighten to 15 Nm (11 lb-ft). 12. Connect the wiring harness clip to the frame. 13. Connect the EVAP canister vent electrical connector. 14. Install the LH shock absorber lower bolt. ^ Tighten to 275 Nm (203 lb-ft). 15. Install both upper arms. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement Suspension Spring ( Coil / Leaf ): Removal and Replacement Front Shock Absorber and Spring Assembly Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7132 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. Remove and discard the 3 shock absorber upper mount nuts. 3. Remove the wheel and tire. 4. Using a suitable jack, support the lower control arm near the lower ball joint. 5. Remove and discard the stabilizer bar link nut and grommet and then remove the stabilizer bar link. 6. Remove and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint nut. 8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 9. While lowering the suspension, remove the shock and spring assembly. Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). This will prevent unequal clamp load and bushing damage. NOTE: For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 1. Install the shock absorber and spring assembly. 2. Connect the upper ball joint to the wheel knuckle and install the upper ball joint nut. ^ Tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7133 3. NOTE: Do not tighten the bolt at this time. Install the shock absorber lower bolt and flag nut. 4. Using a suitable jack, raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). 5. Install the stabilizer bar link. ^ Tighten to 35 Nm (26 lb-ft). 6. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 7. Install the 3 shock absorber upper mount nuts. ^ Tighten to 30 Nm (22 lb-ft). 8. Remove the jack. 9. Install the wheel and tire. 10. Check and if necessary, align the front end. Rear Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7134 1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. ^ To install, tighten to 30 Nm (22 lb-ft). 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7135 Suspension Spring ( Coil / Leaf ): Overhaul Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7136 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock or bushing may occur. NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 lb-ft). 4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7137 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Front Suspension Shock Absorber and Spring Assembly Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7142 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. Remove and discard the 3 shock absorber upper mount nuts. 3. Remove the wheel and tire. 4. Using a suitable jack, support the lower control arm near the lower ball joint. 5. Remove and discard the stabilizer bar link nut and grommet and then remove the stabilizer bar link. 6. Remove and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint nut. 8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 9. While lowering the suspension, remove the shock and spring assembly. Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). This will prevent unequal clamp load and bushing damage. NOTE: For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 1. Install the shock absorber and spring assembly. 2. Connect the upper ball joint to the wheel knuckle and install the upper ball joint nut. ^ Tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7143 3. NOTE: Do not tighten the bolt at this time. Install the shock absorber lower bolt and flag nut. 4. Using a suitable jack, raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). 5. Install the stabilizer bar link. ^ Tighten to 35 Nm (26 lb-ft). 6. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 7. Install the 3 shock absorber upper mount nuts. ^ Tighten to 30 Nm (22 lb-ft). 8. Remove the jack. 9. Install the wheel and tire. 10. Check and if necessary, align the front end. Rear Suspension Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7144 1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. ^ To install, tighten to 30 Nm (22 lb-ft). 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7145 Suspension Strut / Shock Absorber: Overhaul Front Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7146 result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock or bushing may occur. NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 lb-ft). 4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7147 Rear Shock Absorber and Spring Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7148 Shock Absorber and Spring Assembly Disassembly and Assembly 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7149 3. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock bushing may occur. NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 lb-ft). 4. Remove the shock absorber. 5. Remove the shock absorber upper mount. 6. Remove the upper mount bushing. 7. Carefully release the spring compressor and remove the coil spring. 8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening the shock rod nut. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Trailing Arm Trailing Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Page 7154 when removed or incorrect clamp load and damage to components may occur. 1. Remove the toe link. 2. Remove the parking brake cable bracket bolt. ^ To install, tighten to 10 Nm (89 lb-inch). 3. Remove and discard the trailing arm bolt. ^ To install, tighten to 300 Nm (222 lb-ft) at curb height. 4. Remove the 3 wheel knuckle bolts and the trailing arm. ^ Discard the bolts. ^ To install, tighten to 275 Nm (203 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7159 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 3. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7160 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7161 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 components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 lb-inch). 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7162 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut Axle Nut: Specifications Rear Axle Wheel End Nut Rear Axle Wheel End Nut .................................................................................................................... ................................................ 275 Nm (203 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7168 Axle Nut: Specifications Rear Axle Halfshaft Nut Rear Axle Halfshaft Nut ....................................................................................................................... ................................................ 275 Nm (203 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7169 Axle Nut: Specifications Front Axle Wheel End Nut Front Axle Wheel End Nut ................................................................................................................... ................................................ 200 Nm (148 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7170 Axle Nut: Specifications Front Axle Halfshaft Nut Front Axle Halfshaft Nut ...................................................................................................................... ............................................... 250 Nm (184 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. - Under no circumstances should the vehicle ever be lifted by the front or rear control arms, halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to bumper covers will occur. - To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. - When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. - Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Jacking Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7175 Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7181 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7182 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7185 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7186 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7187 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7188 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7189 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7190 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Tire Pressure Monitoring System (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. Tire Pressure Monitoring System (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. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate. 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 Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. Tire Pressure Monitoring System (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 not received any 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7199 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 7200 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7203 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7204 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7205 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7206 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7207 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7208 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7217 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7218 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7219 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7225 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7226 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7227 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7236 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 7241 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7246 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7247 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7252 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7253 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7259 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 7264 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7269 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7270 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7275 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7276 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7281 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the halfshaft nut and washer. ^ To install, tighten to 250 Nm (184 lb-ft). 3. Using the special tool, separate the outboard constant velocity (CV) joint from the wheel hub. 4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7282 Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. ^ To install, tighten to 8 Nm (71 lb-inch). 7. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7283 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 components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 lb-inch). 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7284 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7293 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7299 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut Axle Nut: Specifications Rear Axle Wheel End Nut Rear Axle Wheel End Nut .................................................................................................................... ................................................ 275 Nm (203 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7305 Axle Nut: Specifications Rear Axle Halfshaft Nut Rear Axle Halfshaft Nut ....................................................................................................................... ................................................ 275 Nm (203 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7306 Axle Nut: Specifications Front Axle Wheel End Nut Front Axle Wheel End Nut ................................................................................................................... ................................................ 200 Nm (148 lb-ft). Discard the wheel end nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Rear Axle Wheel End Nut > Page 7307 Axle Nut: Specifications Front Axle Halfshaft Nut Front Axle Halfshaft Nut ...................................................................................................................... ............................................... 250 Nm (184 lb-ft). Install a new halfshaft nut and washer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts ........................................................................................................................................................... 135 Nm (100 lb-ft). in a star pattern Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Removal 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Using the special tool, remove the wheel stud. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7313 Installation 1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats against the flange. ^ Discard the wheel nut and washers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7314 Wheel Fastener: Service and Repair Rear Wheel Studs Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7315 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure 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, or incorrect clamp load and component damage may occur. 1. Remove the wheel and tire. 2. CAUTION: Care must be used when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings can occur. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 3. Remove the brake disc. 4. Remove the parking brake shoe adjuster spring and adjuster. 5. NOTE: The brake shield has an access hole knockout that must be removed to allow for the removal of the wheel stud. Using a suitable punch, remove the access hole cover from the brake shield. 6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle. Using the special tool, press the wheel stud until it makes contact with the edge of the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7316 7. Route the wheel stud through the access hole and discard the wheel stud. Installation 1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side of the wheel extension. ^ Discard the wheel nut and washers. 3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Install a plug into the access hole on the brake shield. 4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake caliper and install the bolts. ^ Tighten to 32 Nm (24 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation SUCTION ACCUMULATOR NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced. The suction accumulator is located at the RH rear of the engine compartment. The suction accumulator is used to prevent residual liquid refrigerant from reaching the A/C compressor after leaving the evaporator core. The suction accumulator allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 7321 Accumulator HVAC: Service and Repair SUCTION ACCUMULATOR Removal and Installation CAUTION: Care must be taken to minimize exposure of the inside of the suction accumulator to outside air. If multiple air conditioning (A/C) system components are being removed and installed, the suction accumulator should be installed last. The suction accumulator shipping caps should not be removed until the fittings are ready to be connected. Evacuation of the A/C system must be started as soon as the suction accumulator is installed. Excessive exposure of the inside of the suction accumulator to outside air will result in moisture contamination of the suction accumulator desiccant. NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced. All vehicles 1. Recover the refrigerant. 2. Remove the PCM. 3. Disconnect the A/C cycling switch electrical connector. 4. Remove the suction accumulator bolt. - To install, tighten to 11 Nm (8 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 7322 5. Remove the PCM bracket bolt. 6. Remove the PCM bracket nut and the PCM bracket. 7. Remove the suction accumulator stud. - To install, tighten to 11 Nm (8 lb-ft). 4.6L vehicles 8. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator line bracket. All vehicles 9. Remove the suction accumulator bracket bolt and suction accumulator. 10. Remove the 2 suction accumulator fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 11. Remove the suction accumulator. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver Air Door Actuator / Motor: Locations Temperature Blend Door Actuator, Driver View 151-38 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7328 View 151-39 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7329 View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7330 View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7331 View 151-39 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear C3004 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7334 C2091 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7335 C2092 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7336 C3044 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7337 Actuator - Temperature Blend Door, Electronic Automatic Temperature Control (EATC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH TEMPERATURE BLEND DOOR ACTUATOR - LH Removal and Installation 1. Remove the LH floor console finish panel. 2. Position the in-vehicle temperature sensor aspirator hose away from the LH temperature blend door actuator. 3. Remove the 3 LH temperature blend door actuator screws. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the LH temperature blend door actuator. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7340 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH, EATC TEMPERATURE BLEND DOOR ACTUATOR - RH, EATC Removal and Installation 1. Remove the RH floor console finish panel. 2. Lower the glove compartment. 3. Disconnect the RH temperature blend door actuator electrical connector. 4. Remove the 3 RH temperature blend door actuator screws. 5. Remove the RH temperature blend door actuator. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7341 Air Door Actuator / Motor: Service and Repair Auxiliary Mode Door Actuator AUXILIARY MODE DOOR ACTUATOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7342 4. Remove the 2 auxiliary heater core and evaporator core housing bolts. - To install, tighten to 6 Nm (53 lb-in). 5. Remove the auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). 6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary mode door actuator electrical connector. 8. Remove the 3 auxiliary mode door actuator screws. 9. Remove the auxiliary mode door actuator. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7343 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor - Defroster Door VACUUM CONTROL MOTOR - DEFROSTER DOOR Removal and Installation 1. Remove the audio control module (ACM). 2. Remove the lower steering column cover. 3. Remove the 3 center panel duct screws and position the center panel duct aside. 4. Remove the 2 plenum chamber screws. 5. Disconnect the defrost door vacuum control motor vacuum connector. 6. Remove the 2 defrost door vacuum control motor screws. 7. NOTE: The plenum chamber must be slightly repositioned to allow the defrost door vacuum control motor to be rotated far enough to clear the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7344 retaining arm. Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the defrost door vacuum control motor. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7345 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH TEMPERATURE BLEND DOOR ACTUATOR - LH Removal and Installation 1. Remove the LH floor console finish panel. 2. Position the in-vehicle temperature sensor aspirator hose away from the LH temperature blend door actuator. 3. Remove the 3 LH temperature blend door actuator screws. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the LH temperature blend door actuator. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7346 Temperature Blend Door Actuator - RH, EATC TEMPERATURE BLEND DOOR ACTUATOR - RH, EATC Removal and Installation 1. Remove the RH floor console finish panel. 2. Lower the glove compartment. 3. Disconnect the RH temperature blend door actuator electrical connector. 4. Remove the 3 RH temperature blend door actuator screws. 5. Remove the RH temperature blend door actuator. 6. To install, reverse the removal procedure. Auxiliary Mode Door Actuator AUXILIARY MODE DOOR ACTUATOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7347 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 auxiliary heater core and evaporator core housing bolts. - To install, tighten to 6 Nm (53 lb-in). 5. Remove the auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7348 6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary mode door actuator electrical connector. 8. Remove the 3 auxiliary mode door actuator screws. 9. Remove the auxiliary mode door actuator. 10. To install, reverse the removal procedure. Vacuum Control Motor - Defroster Door VACUUM CONTROL MOTOR - DEFROSTER DOOR Removal and Installation 1. Remove the audio control module (ACM). 2. Remove the lower steering column cover. 3. Remove the 3 center panel duct screws and position the center panel duct aside. 4. Remove the 2 plenum chamber screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7349 5. Disconnect the defrost door vacuum control motor vacuum connector. 6. Remove the 2 defrost door vacuum control motor screws. 7. NOTE: The plenum chamber must be slightly repositioned to allow the defrost door vacuum control motor to be rotated far enough to clear the retaining arm. Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the defrost door vacuum control motor. 8. To install, reverse the removal procedure. Vacuum Control Motor - Floor Door VACUUM CONTROL MOTOR - FLOOR DOOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7350 Removal and Installation 1. Remove the center instrument panel finish panel. 2. Remove the shield screw. 3. Remove the shield. 4. Lower the glove compartment. 5. Disconnect the floor door vacuum control motor vacuum connector. 6. Detach the instrument panel harness pin-type retainer and position the harness aside. 7. Remove the 2 floor door vacuum control motor screws. 8. Remove the RH floor console finish panel. 9. NOTE: The retaining arm must be slightly deflected away from the vacuum control motor arm to provide clearance. Partially actuate and rotate the floor door vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 10. To install, reverse the removal procedure. Vacuum Control Motor - Panel Door VACUUM CONTROL MOTOR - PANEL DOOR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7351 Removal and Installation 1. Remove the audio control module (ACM). 2. Lower the glove compartment. 3. Remove the 3 center panel duct screws and position the center panel duct aside. 4. Remove the 2 plenum chamber screws. 5. Disconnect the panel door vacuum control motor vacuum connector. 6. Remove the 2 panel door vacuum control motor screws. 7. NOTE: The plenum chamber must be slightly repositioned to allow the panel door vacuum control motor to be rotated far enough to clear the retaining arm. Rotate the panel door vacuum control motor until it clears the retaining arm and remove the panel door vacuum control motor. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7352 Auxiliary Temperature Blend Door Actuator AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 auxiliary heater core and evaporator core housing bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7353 - To install, tighten to 6 Nm (53 lb-in). 5. Remove auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). 6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary temperature blend door actuator electrical connector. 8. Remove the 3 auxiliary temperature blend door actuator screws. 9. Remove the auxiliary temperature blend door actuator. 10. To install, reverse the removal procedure. Vacuum Control Motor - Air Inlet Door VACUUM CONTROL MOTOR - AIR INLET DOOR Removal and Installation 1. Lower the glove compartment. 2. Remove the screws and the heater core and evaporator core housing support brace. 3. Disconnect the air inlet door vacuum control motor vacuum connector. 4. Remove the 2 air inlet door vacuum control motor screws. 5. Rotate the air inlet door vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Vacuum Solenoid Valve, HVAC > Component Information > Testing and Inspection Automatic Temperature Control (ATC) Solenoid and Manifold Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair Air Duct: Service and Repair AIR INLET DUCT Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the air inlet duct. 1 Remove the support bracket screw. 2 Disconnect the air inlet door vacuum control motor vacuum connector. 3 Remove the 3 air inlet duct screws. 4 Remove the air inlet duct. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7363 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7364 C132 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7365 Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7366 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 7371 C3021 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 7376 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 7377 View 151-38 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay C3023 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 7380 C2017 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7383 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7384 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7385 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly > Page 7390 View 151-38 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor Assembly C293 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor Assembly > Page 7393 C3022 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 7394 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR The blower motor resistor has 3 resistor elements mounted on the resistor board to provide 4 blower motor speeds. Depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. The blower motor resistor has an overheating device (thermal limiter) that opens the resistor coil when the temperature reaches approximately 184°C (363°F), interrupting the blower motor operation in all speeds except HIGH. The thermal limiter cannot be reset and is not serviceable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor, Front Resistor - Blower Motor, Front Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor, Front > Page 7397 Resistor - Blower Motor, Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Remove the two 4X4 control module screws. 2. Disconnect the blower motor resistor electrical connector. 3. Remove the 2 blower motor resistor screws. 4. Remove the blower motor resistor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 7400 Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor AUXILIARY BLOWER MOTOR RESISTOR Removal and Installation 1. Remove the switch bezel. 2. Disconnect the power lock switch electrical connector. 3. Remove the access panel. 4. Disconnect the auxiliary blower motor resistor electrical connector. 5. Remove the 2 auxiliary blower motor resistor screws. 6. Remove the auxiliary blower motor resistor. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations View 151-39 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7404 C271 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7405 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 switch resistor in all function selector switch positions except OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7406 Switch - Blower Motor, Front Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7407 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not factory equipped with a Cabin Air Filter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7414 C233 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7415 Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7416 Cabin Temperature Sensor / Switch: Service and Repair 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification A/C Compressor Magnetic Clutch Air gap clearance.................................................................................................................................. ...................................0.35-0.65 mm (0.014-0.026 in) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7421 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations Compressor Clutch Coil: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7425 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7426 C1110 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7427 Compressor Clutch Coil: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7428 Removal All vehicles 1. Remove the A/C compressor. 2. Remove the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Remove the A/C clutch disc and hub bolt. 3. Remove the A/C clutch disc and hub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7429 4. Remove the A/C compressor pulley snap ring. 5. Remove the A/C compressor pulley. 1 Install the special tool. 2 Remove the A/C compressor pulley. FS18 compressors only 6. CAUTION: Do not use air tools. The air conditioning (A/C) clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1 Install the special tool. 2 Install the special tool. 3 Remove the A/C clutch field coil. FS20 compressors only 7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch field coil electrical connector screw. 9. Remove the A/C clutch field coil. Installation NOTE: If installing a new A/C compressor, 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/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. All vehicles 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. FS18 compressors only 3. CAUTION: Do not use air tools. The air conditioning (A/C) clutch field coil can be easily damaged. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the special tool on the A/C clutch field coil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7430 3 Place the special tool 412-065 on the special tool 412-078. 4 Use the special tool to install the A/C clutch field coil. FS20 compressors only 4. Install the A/C clutch field coil. 5. Install the A/C clutch field coil electrical connector screw. 6. Install the A/C clutch field coil snap ring. All vehicles 7. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. Install the A/C clutch pulley. 8. Install the A/C clutch pulley snap ring with the bevel side out. 9. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 10. Install the A/C clutch disc and hub assembly. 11. Install the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Install the A/C clutch disc and hub bolt. - Tighten to 14 Nm (10 lb-ft). 12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 13. Install the A/C compressor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7434 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7435 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation CONDENSER CORE The condenser 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7439 Condenser HVAC: Service and Repair CONDENSER CORE Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7440 Part 2 Removal and Installation 1. Recover the refrigerant. 2. Remove the air cleaner (ACL). 3. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 4. Disconnect the A/C pressure transducer electrical connector. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 7. Detach the 2 compressor-to-condenser discharge line clips. 8. Remove the 2 cooling module bolts and position the cooling module rearward. - To install, tighten to 12 Nm (9 lb-ft). 9. Remove the upper radiator air deflector. 10. Remove the 2 condenser core bolts. - To install, tighten to 12 Nm (9 lb-ft). 11. Remove the condenser core. 12. Remove the 2 condenser air deflectors. 13. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 14. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 Control Assembly: Connector Views C294A C294B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 C294C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 C951A C951B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7461 Control Assembly: Description and Operation FUNCTION SELECTOR SWITCH The function selector switch combines a vacuum selector valve that determines air distribution and an electrical switch to supply battery voltage to the A/C compressor circuit and the blower motor circuit. When the function selector switch is in the MAX A/C, DEFROST or FLOOR/DEFROST positions, the A/C compressor will be operational regardless of the A/C request switch status. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Switch - Function Selector Switch - Function Selector Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Switch - Function Selector > Page 7464 Climate Control Assembly - Front Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1. Remove the center instrument panel finish panel. 2. Remove the 4 climate control assembly screws. 3. Remove the climate control assembly. 4. Remove the 3 climate control knobs. 5. Depress the tabs and remove the blower motor switch. 6. Depress the tabs and remove the function selector switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 7467 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 7468 Control Assembly: Service and Repair Auxiliary Climate Control Assembly AUXILIARY CLIMATE CONTROL ASSEMBLY Removal and Installation 1. Remove the overhead console. 2. Remove the 2 screws. 3. Remove the bezel. 4. Remove the auxiliary climate control assembly. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 7469 Control Assembly: Service and Repair Heating Ventilation Air Conditioning (HVAC) Module HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE Removal and Installation NOTE: If installing a new HVAC module, the new module must be configured for the vehicle. 1. Remove the center instrument panel finish panel. 2. Remove the 4 HVAC module screws. 3. Remove the HVAC module. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7473 Control Module HVAC: Diagrams C228A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7474 C228B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 may cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. Push the Refrigerant Coupling Spring Remover 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 air conditioning (A/C) tube lock coupling spring; this may cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Remove the spring lock coupling spring with a small hooked wire. Connect 1. Install the spring lock coupling spring. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 7478 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation EVAPORATOR CORE NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7482 Evaporator Core: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. Refer to Spring Lock Coupling. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7483 Evaporator Core: Service and Repair 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. 1. Remove the heater core. 2. Remove the 5 outer evaporator core cover screws. 3. Remove the 6 inner evaporator core cover screws. 4. Separate the evaporator core cover from the heater core and evaporator core housing. - Discard the rope seal. 5. Remove the evaporator core. 6. To install, reverse the removal procedure. - Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of the rope seal. - Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant evenly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Evaporator Drain Tube: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 7492 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Evaporator Drain Tube: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 7498 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation Evaporator Core Orifice NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is installed. The evaporator core orifice is located in the condenser-to-evaporator line, and can be removed through an access fitting. The evaporator core orifice 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. A/C Pressure Transducer The A/C pressure transducer is used by the PCM to monitor the discharge pressure in the high-pressure side of the refrigerant system. When the A/C pressure transducer is reading a discharge pressure above acceptable levels, the PCM will disengage the A/C compressor clutch. The A/C pressure transducer is installed on a Schrader-type valve core fitting on the compressor-to-condenser discharge line. It is not necessary to recover the refrigerant before removing the A/C pressure transducer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 7505 Expansion Block/Orifice Tube: Service and Repair EVAPORATOR CORE ORIFICE Special Tool(s) Special Tool(s) Removal 1. Recover the refrigerant. 2. NOTE: The evaporator core orifice access fitting is located in the condenser-to-evaporator line below the powertrain control module. Disconnect the evaporator core orifice access fitting. Discard the O-ring seal. 3. Inspect the evaporator core orifice for damage before attempting to remove it from the line. 4. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 7506 5. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Installation 1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core orifice using the special tool. 2. Install a new O-ring seal and connect the evaporator core orifice access fitting. - To install, tighten to 18 Nm (13 lb-ft). 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. 4. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMOSTATIC EXPANSION VALVE Removal and Installation NOTE: An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan bracket connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve (TXV). This filter must be inspected before a new TXV is installed. 1. Recover the refrigerant. 2. Remove the D-pillar trim panel. 3. Detach the rear portion of the LH quarter trim panel and position away from the TXV. 4. Remove the 4 clips and the TXV cover. 5. Remove the insulating tape. - Retain the tape for reuse. 6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the evaporator outlet line. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7510 7. Disconnect the 2 TXV fittings and remove the TXV. - Discard the O-ring seals. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 9. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair HEATER CONTROL VALVE Removal and Installation Vehicles with 4.0L and oil cooler, without auxiliary climate control 1. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect the heater control valve vacuum hose. Vehicles with 4.0L and oil cooler, without auxiliary climate control 5. Remove the heater control valve bolt. All vehicles 6. Remove the heater control valve. 7. NOTE: Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. 8. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection Heater Core: Testing and Inspection HEATER CORE 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the heater control valve may be stuck closed. - the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Page 7517 5. If a leak is observed, replace the heater core. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 pressure leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3. Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6. Remove the 3 housing brace screws. 7. Remove the housing brace. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7520 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. 10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7521 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7522 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Release the 2 heater hose clamps and disconnect the heater hoses. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7523 4. Remove the rear quarter trim panel. 5. Remove the 2 auxiliary line floorpan bracket nuts. 6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket. Remove the 4 line bracket screws and the line bracket. 7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts and auxiliary housing nut. - To install, tighten to 6 Nm (53 lb-in). 9. Disconnect the 2 auxiliary actuator electrical connectors. 10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15. Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the auxiliary heater core. 18. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only if needed. 19. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 7528 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 7529 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 PRESSURE RELIEF VALVE NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring. If the A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction. An A/C compressor pressure relief valve is installed in the compressor to relieve unusually high refrigerant system discharge pressure buildups. The compressor pressure relief valve will avoid total refrigerant loss by closing after the excessive pressure has been relieved. The A/C pressure relief valve is a separate component and can be replaced separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 7533 High Pressure Safety Valve HVAC: Service and Repair AIR CONDITIONING (A/C) PRESSURE RELIEF VALVE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the A/C compressor pressure relief valve and O-ring seal. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service part. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. 5. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the compressor outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7538 - To install, tighten to 8 Nm (71 lb-in). 9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected from the cooling module. Detach the 2 compressor-to-condenser discharge line clips at the cooling module. 10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7539 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the PCM and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7540 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 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. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7541 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7542 Part 2 Removal and Installation 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7543 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7544 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7545 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the compressor outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet fitting nut and disconnect the fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7546 - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected from the cooling module. Detach the 2 compressor-to-condenser discharge line clips at the cooling module. 10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the PCM and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7547 Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 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. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7548 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7549 Part 2 Removal and Installation 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7550 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7551 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Suction Accumulator To Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7552 Removal and Installation 1. Recover the refrigerant. 2. Remove the suction accumulator outlet fitting nut. - To install, tighten to 8 Nm (71 lb-in). 3. Disconnect the auxiliary evaporator outlet line fitting. - Discard the O-ring seals. 4. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the rear suction accumulator-to-compressor line. - Discard the O-ring seal. 7. NOTE: The compressor suction fitting nut can be accessed through the RH wheel well. Remove the compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7553 8. Remove the front suction accumulator-to-compressor line. 9. To install, reverse the removal procedure. - Install new O-ring seals and a new gasket seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Suction Accumulator To Evaporator Line SUCTION ACCUMULATOR TO EVAPORATOR LINE Removal and Installation All vehicles 1. Remove the suction accumulator. 2. Remove the A/C line bracket nut at the dash panel and remove the A/C line bracket. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the ground strap bolt at the dash panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7554 4. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Vehicles with 4.0L engine 5. Disconnect he evaporative emissions return line fitting at the intake manifold. 6. Remove the fuel line bracket bolt at the rear of the RH valve cover. 7. Remove the wire harness bolt at the rear of the RH cylinder head. All vehicles 8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7555 - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor Housing Assembly HVAC: Customer Interest A/C - Water Leak Onto Driver's Side Floor TSB 08-17-5 09/01/08 WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008 FORD: 2008 Explorer Sport Trac, Explorer MERCURY: 2008 Mountaineer ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum assembly. This may be due to condensation from the A/C lines leaking between the plenum case and the A/C evaporator gasket at the bulkhead. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The evaporator gasket may get caught on or push through the A/C line access hole at the bulk head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure 1) NOTE THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A FINGER. (FIGURE 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor > Page 7564 NOTE THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking between the plenum case and the bulkhead. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081705A 2008 Explorer, 0.2 Hr. Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the Vehicle Bulkhead. DEALER CODING CONDITION BASIC PART NO. CODE 18658 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor Housing Assembly HVAC: All Technical Service Bulletins A/C - Water Leak Onto Driver's Side Floor TSB 08-17-5 09/01/08 WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008 FORD: 2008 Explorer Sport Trac, Explorer MERCURY: 2008 Mountaineer ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum assembly. This may be due to condensation from the A/C lines leaking between the plenum case and the A/C evaporator gasket at the bulkhead. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The evaporator gasket may get caught on or push through the A/C line access hole at the bulk head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure 1) NOTE THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A FINGER. (FIGURE 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor > Page 7570 NOTE THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking between the plenum case and the bulkhead. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081705A 2008 Explorer, 0.2 Hr. Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the Vehicle Bulkhead. DEALER CODING CONDITION BASIC PART NO. CODE 18658 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing HEATER CORE AND EVAPORATOR CORE HOUSING Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Lubricate the coolant hoses with plain water only if needed. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. 4. Detach the wiring harness bracket and position the harness aside. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7573 5. Remove the heater tube bracket nut. 6. Remove the dash panel A/C line bracket nut. - To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the 2 heater hose clamps at the heater core. 8. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 9. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. 10. Disconnect the 2 vacuum connectors. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7574 11. Detach the grommet and push the vacuum lines into the passenger compartment. 12. Remove the 4 heater core and evaporator core housing nuts. - To install, tighten to 9 Nm (80 lb-in). 13. Disconnect the ground terminal bolt. 14. Remove the heater core and evaporator core housing. 15. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 16. Fill and the engine cooling system. 17. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7575 Housing Assembly HVAC: Service and Repair Plenum Chamber PLENUM CHAMBER Removal and Installation 1. Remove the instrument panel. 2. Remove the audio unit. 3. Remove the 3 plenum chamber screws. 4. Remove the instrument panel upper finish panel. 5. Remove the 3 defroster duct screws. 6. Remove the defroster duct. 7. Remove the plenum chamber. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7576 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing AUXILIARY HEATER CORE AND EVAPORATOR CORE HOUSING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7577 Removal and Installation NOTE: Clean and lubricate the coolant hoses with plain water only if needed. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Drain the engine coolant. 4. Remove the LH quarter trim panel. 5. Detach the headliner duct from the auxiliary climate control housing. 6. Remove the auxiliary evaporator inlet and outlet line fitting nuts. - Discard the O-ring seals. - Discard the thermostatic expansion valve (TXV) filter. - To install, tighten to 8 Nm (71 lb-in). 7. Release the heater hose clamps and disconnect the heater hoses. - After disconnecting the heater hoses, allow any residual coolant to drain from the auxiliary heater core to avoid coolant spilling inside the passenger compartment. 8. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary heater core and evaporator core housing bolts. - To install, tighten to 6 Nm (53 lb-in). 10. Remove the auxiliary heater core and evaporator core housing nut. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7578 - To install, tighten to 6 Nm (53 lb-in). 11. Disconnect the auxiliary harness electrical connector. 12. Remove the auxiliary heater core and evaporator core housing. 13. To install, reverse the removal procedure. - Clean and lubricate the coolant hoses with plain water only if needed. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 14. Fill the engine cooling system. 15. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A (Specification) - 0.88 kg (31 oz) (vehicles without auxiliary systems) (Fill Capacity) R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A (Specification) - 1.33 kg (47 oz) (vehicles with auxiliary systems) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7583 Refrigerant: Fluid Type Specifications R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A (Specification) - 0.88 kg (31 oz) (vehicles without auxiliary systems) (Fill Capacity) R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A (Specification) - 1.33 kg (47 oz) (vehicles with auxiliary systems) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Climate Control System PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B (Specification) - 266 ml (9 fl oz) (vehicles without auxiliary systems) (Fill Capacity) PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B (Specification) - 473 ml (16 fl oz) (vehicles with auxiliary systems) (Fill Capacity) Auxiliary Climate Control PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B (Specification) - 47 ml (16 fl oz) (with auxiliary climate control) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7588 Refrigerant Oil: Fluid Type Specifications Climate Control System PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B (Specification) - 266 ml (9 fl oz) (vehicles without auxiliary systems) (Fill Capacity) PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B (Specification) - 473 ml (16 fl oz) (vehicles with auxiliary systems) (Fill Capacity) Auxiliary Climate Control PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B (Specification) - 47 ml (16 fl oz) (with auxiliary climate control) (Fill Capacity) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7592 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch C130 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 7595 C1078 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C compressor clutch when the suction pressure in the low-pressure side of the refrigerant system drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage the A/C compressor clutch. The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator. It is not necessary to recover the refrigerant before removing the A/C cycling switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7598 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 Air Conditioning System Overview. 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. 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. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7599 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay View 151-40 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 7605 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 7606 View 151-38 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay C3023 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 7609 C2017 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7612 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7613 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7614 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7618 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7619 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7623 Control Module HVAC: Diagrams C228A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7624 C228B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7629 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7630 C132 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7631 Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7632 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-39 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7636 C271 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7637 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 switch resistor in all function selector switch positions except OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7638 Switch - Blower Motor, Front Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7639 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7643 C233 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7644 Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7645 Cabin Temperature Sensor / Switch: Service and Repair 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7652 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch C130 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 7655 C1078 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C compressor clutch when the suction pressure in the low-pressure side of the refrigerant system drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage the A/C compressor clutch. The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator. It is not necessary to recover the refrigerant before removing the A/C cycling switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7658 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 Air Conditioning System Overview. 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. 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. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7659 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 7663 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 compressor-to-condenser discharge line. The low-pressure service gauge port valve is located on the suction accumulator. The fitting is an integral part of the A/C 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 7670 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR - MINI-TUBE Special Tool(s) Special Tool(s) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 in) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 in) into the ends of the standard 1/8-inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the vacuum pump or equivalent. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM RESERVOIR Removal and Installation 1. Remove the vacuum reservoir screw. 2. Remove the vacuum reservoir. 3. Disconnect the vacuum connector. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 7680 C2093 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. - Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. - Always refer to the appropriate Vehicle System procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. - 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 Vehicle System. See: Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset 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 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 weight sensor bolts. - 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. 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 - 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7686 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be worked back to its original shape and structural integrity. 2. Install the new safety belt(s). Carry out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Adaptive Collapsible Steering Column > Component Information > Service and Repair Adaptive Collapsible Steering Column: Service and Repair DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury. 1. Depower the SRS. 2. NOTE: It may be necessary to lower or remove the deployable steering column from the instrument panel to access the deployable steering column electrical connector. Access the deployable steering column electrical connector. 3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering column. Cut each of the deployable steering column wires, leaving at least 4 inches to work with. 4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5. Make a jumper harness to deploy the deployable steering column. - Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire. - At one end of the jumper harness, connect the wires together. 6. Using the end of the jumper harness that the wires are not connected together, attach each wire of the jumper harness to each wire of the deployable steering column. Use tape or other insulating material to make sure that the leads do not make contact with each other. 7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of the jumper harness from each other. 9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column. 11. Dispose of the deployed steering column in the same manner as any other part to be scrapped. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7695 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7696 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7697 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7698 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7699 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7700 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7701 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7702 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7703 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7704 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7705 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7706 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7707 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 7712 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 7713 View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 C216A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7716 C216B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7717 C367 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7718 C337 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7719 Air Bag: Diagrams C216A C216B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7720 C367 C337 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7721 C256 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7722 C3213 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7723 C9006 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7724 C3214 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7725 C9007 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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. 1. Depower the SRS. 2. Remove the 2 driver air bag module bolts. - To install, tighten to 7 Nm (62 lb-in). 3. 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. Damage to the connector or component may occur. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7728 NOTE: Note the position of the locator holes in the back of the driver air bag module and locator tabs on the steering wheel for installation. Disconnect the 3 electrical connectors and remove the driver air bag module. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7729 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE Removal and Installation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not repaint air bag modules with discolored or damaged trim covers or deployment doors; new air bag modules must be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7730 Failure to follow this instruction may result in the air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator 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. 1. Depower the SRS. 2. Open and lower the glove compartment door. 3. Release the wiring retainer, then remove the 4 bolts and the passenger air bag module heat shield. 4. Through the glove compartment opening, disconnect the 2 passenger air bag module electrical connectors. 5. Through the glove compartment opening, remove the 4 passenger air bag module nuts. - 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 doors. Damage to the air bag module may occur. Through the glove compartment opening, push up to release the deployment door clips from the instrument panel (I/P) and push the passenger air bag module out of the I/P and remove. 7. NOTE: During air bag module installation, make sure all the deployment door clips are fully seated into the I/P. To install, reverse the removal procedure. 8. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7731 Air Bag: Service and Repair Safety Canopy Module SAFETY CANOPY MODULE Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7732 Part 2 Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live safety canopy, or side air curtain module, with the module and tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment. - Anytime the safety canopy or side air curtain module has deployed, a new headliner and new A-, B- and C-pillar upper trim panels and attaching hardware must be installed. Remove any other damaged components and hardware and install new components and hardware as needed. Failure to follow these instructions may result in the safety canopy or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. - When installing a new headliner on a vehicle equipped with safety canopy or side air curtain modules, make sure the headliner has the word AIRBAG on the headliner where it meets each B-pillar trim panel. Otherwise, you have the wrong headliner. Failure to follow this instruction may result in the safety canopy or side air curtain module not deploying or deploying incorrectly, increasing the risk of personal injury or death in a crash. - Before installing a safety canopy or side air curtain module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. Install new fasteners if damaged and remove foreign material. Failure to follow these instructions may result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Inspect a safety canopy or side air curtain module before installation. If the module is damaged, the cover has separated or the safety canopy/side air curtain material has been exposed, install a new module. Do not attempt to repair the module. Failure to follow these instructions may result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Do not obstruct or place objects in the deployment path of the safety canopy or side air curtain module. Failure to follow this instruction may result in the safety canopy or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. - Never put any type of fastener or tie strap around any part of a safety canopy module, side air curtain module or interior trim panel. This will prevent the safety canopy or side air curtain module from deploying correctly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Always use new torque-prevailing type J-nuts when installing the safety canopy in the vehicle. Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to follow this instruction may result in the safety canopy module deploying incorrectly and increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator 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. - RH shown, LH similar. All vehicles 1. Depower the SRS. 2. Remove the headliner. Vehicles with moon roof 3. NOTE: Note the position of the 2 rear moon roof drain hose routing clips for installation. Disconnect the rear moon roof drain tube and detach the 2 rear moon roof drain hose routing clips. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7733 All vehicles 4. Disconnect the safety canopy module electrical connector and detach the connector pin-type retainer from the C-pillar. 5. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheet metal for installation. Remove the bolt and the front tether anchor bracket. 6. Detach the 3 safety canopy module front tether pin-type retainers from the A-pillar. 7. Remove the 3 front bolts from the safety canopy module. 8. Remove the 2 rear bracket bolts from the safety canopy module. 9. Remove the 2 bolts and the safety canopy module C-pillar tether bracket. 10. Remove the 2 safety canopy module bolts near the C-pillar. 11. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook from the sheet metal. 12. Move the safety canopy module forward to release the rear bracket hook from the sheet metal and remove the safety canopy module. Installation WARNING: - Before installing a safety canopy or side air curtain module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. Install new fasteners if damaged and remove foreign material. Failure to follow these instructions may result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Inspect a safety canopy or side air curtain module before installation. If the module is damaged, the cover has separated or the safety canopy/side air curtain material has been exposed, install a new module. Do not attempt to repair the module. Failure to follow these instructions may result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7734 - Never put any type of fastener or tie strap around any part of a safety canopy module, side air curtain module or interior trim panel. This will prevent the safety canopy or side air curtain module from deploying correctly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. - Always use new torque-prevailing type J-nuts when installing the safety canopy in the vehicle. Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to follow this instruction may result in the safety canopy module deploying incorrectly and increases the risk of serious personal injury or death in a crash. All vehicles 1. Remove the front 4 J-nuts and install new. 2. Remove the rear 4 J-nuts and install new. 3. Position the safety canopy module by moving it rearward, installing the rear bracket hook in the sheet metal. 4. Install the safety canopy module B-pillar bracket hook in the sheet metal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7735 5. NOTE: Make sure all safety canopy module bolt holes line up with all J-clips. Install the 2 safety canopy module bolts near the C-pillar. Tighten to 8 Nm (71 lb-in). 6. Install the safety canopy module C-pillar tether bracket and the 2 bolts. - Tighten to 12 Nm (9 lb-ft). 7. Install the 2 safety canopy module rear bracket bolts. - Tighten to 8 Nm (71 lb-in). 8. Install the safety canopy module front 3 bolts. - Tighten to 8 Nm (71 lb-in). 9. Attach the 3 safety canopy module front tether pin-type retainers to the A-pillar. 10. NOTE: Make sure the safety canopy module front tether bracket locator tab is correctly installed in the A-pillar sheet metal. Install the safety canopy module front tether bracket and bolt. Tighten to 8 Nm (71 lb-in). 11. Connect the safety canopy module electrical connector and attach the connector pin-type retainer to the C-pillar. Vehicles with moon roof 12. NOTE: Make sure to route the moon roof drain hose as noted during removal. Connect the rear moon roof drain tube and attach the 2 rear moon roof drain hose clips. All vehicles 13. Install the headliner. 14. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7739 View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7740 View 151-21 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit C216C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7743 Air Bag Control Module: Diagrams Restraints Control Module C310A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7744 C310B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7745 C310B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 7746 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 7747 - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: When installing a new RCM, it is necessary to carry out programmable module installation (PMI). System failure may occur if PMI is not performed. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 7748 5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle may cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. - CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 7749 7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9. Carry out the steps necessary to complete PMI. 10. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 7753 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and Installation NOTE: - The air bag warning indicator 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. 1. Depower the SRS. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel (I/P) center finish panel. 4. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install, reverse the removal procedure. 7. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams C218A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7757 C218B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7758 Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7759 Part 2 Removal NOTE: The air bag warning indicator 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. 1. Remove the driver air bag module. 2. Remove the steering wheel. 3. Remove the 2 screws and the instrument panel (I/P) lower steering column opening cover. 4. Remove the 3 screws and the lower steering column shroud. 5. Remove the upper steering column shroud. 6. Disconnect the clockspring electrical connector. 7. Remove the 2 screws and position aside the steering wheel rotation sensor. 8. Remove the 2 clockspring screws and remove the clockspring. Installation 1. CAUTION: If installing a new clockspring, do not remove the clockspring anti-rotation key until the steering wheel is installed. If the anti-rotation key has been removed before installing the steering wheel, the clockspring must be centered. Failure to follow this instruction may result in component damage and/or system failure. Install the clockspring and the 2 screws. 2. Install the steering wheel rotation sensor and the 2 screws. 3. Connect the clockspring electrical connector. 4. Install the upper steering column shroud. 5. Install the lower steering column shroud and the 3 screws. 6. Install the I/P lower steering column opening cover and the 2 screws. 7. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt, repeat the centralizing procedure. Failure to follow these instructions may increase the risk of serious personal injury or death in a crash. CAUTION: To prevent component damage and/or system failure, when reusing a clockspring it must be centered. - Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected to the clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its internal connection. Failure to follow this instruction may result in component damage and/or system failure. If a new clockspring was installed and the anti-rotation key has not been removed GO to Step 9. If a new clockspring was installed and the anti-rotation key has been removed before the steering wheel is installed or the same clockspring is being installed, rotate the clockspring inner rotor counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance. Stop rotating the clockspring inner rotor at this point. 8. Starting with the clockspring inner rotor, wiring and connector in the 12 o'clock position, rotate the inner rotor clockwise through 2-1/2 revolutions to center the clockspring. The clockspring inner rotor, wiring and connector must be in the 12 o'clock position. 9. CAUTION: To prevent damage to the clockspring, make sure the road wheels are in the straight-ahead position. NOTE: The clockspring inner rotor, wiring and connector must be in the 12 o'clock position to install the steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7760 Install the steering wheel. 10. If a new clockspring was installed, remove the anti-rotation key. 11. Install the driver air bag module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor Impact Sensor: Locations Forward Crash Sensor View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7765 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7766 View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7767 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7768 Impact Sensor: Locations Side Impact Sensor View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7769 View 151-23 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7770 View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7771 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7772 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7773 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor Impact Sensor: Diagrams Forward Crash Sensor C1465 C1466 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 7776 Impact Sensor: Diagrams Side Impact Sensor C567A C644A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 7777 C3248 C3249 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7780 - 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. Depower the SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7781 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint (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. - RH shown, LH similar. - The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7782 5. Position aside the lower C-pillar trim panel. - Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the C-pillar side impact sensor. 6. NOTE: - Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts from the side impact sensor and bracket assembly. - To install, tighten to 12 Nm (9 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7783 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. - Driver side shown, passenger side similar. 1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. NOTE: - Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7784 Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7788 C3159 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7789 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM) Removal and Installation NOTE: - The air bag warning indicator 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 shown, manual seat similar. - Seat is removed for clarity. 1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant classification system module (OCSM) electrical connector. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7790 out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left > Page 7795 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left C3291 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left > Page 7798 C3292 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7799 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification sensor (OCS) system is standard equipment on all front passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7800 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7801 Part 2 Removal WARNING: - The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. - Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: - The air bag warning indicator 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 perform the diagnostic procedure again. - Outboard shown, inboard similar. 1. Remove the passenger seat. 2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then, using a suitable tool, release the tab and disconnect the OCS rail electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7802 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7803 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: - If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. - To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7804 - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat. Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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 shown, manual seat similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Note the position of the seat position sensor locating tab for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Page 7808 Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair Side Air Bag: Service and Repair SIDE AIR BAG MODULE Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: - If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module must be installed. The seat back frame should be replaced if necessary. - When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag module. - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Page 7812 - 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 seat shown, passenger seat similar. 1. Remove the front seat and depower the SRS. 2. Remove the seat backrest. 3. NOTE: RH shown, LH similar. Remove the 2 plastic rivets attaching the backrest trim cover to the inboard and outboard recliners on the seat backrest frame. 4. Release the seat back lower outer trim cover J-clip. 5. Release the seat back lower inner trim cover J-clip. 6. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strips, or the hook-and-loop strip can be torn from the seat backrest foam pad. Place a hand between the seat backrest trim cover and foam pad and carefully separate the hook-and-loop strips, then carefully roll up the seat back trim cover in an inside out fashion to the first row of hog rings in the front. 7. Remove the first row of hog rings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Page 7813 8. Detach the hook-and-loop strips and invert the seat backrest trim cover up enough to expose the side air bag. 9. NOTE: Note the position and the routing of the side air bag module wiring harness for installation. Detach the side air bag wiring harness retainers from the seat backrest frame. 10. Position out the seat backrest foam pad. 11. Remove the 2 bolts and the side air bag module. Installation WARNING: - Inspect the seat side air bag module and mounting surfaces for any damage or foreign material before installing the seat side air bag module. If any damage is found, install new components. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. - Before installing the seat side air bag module/deployment chute assembly: Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame. Damage to the wire harness may occur. All seats 1. Align the holes of the side air bag module bracket to the U-nuts on the backrest frame. - Install new U-nuts if installing a new side air bag module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Page 7814 2. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the backrest frame. 3. Install the side air bag module and the bolts. - Tighten to 10 Nm (89 lb-in). 4. Position back the seat backrest foam pad. 5. Attach the side air bag wiring harness retainers to the seat backrest frame. 6. Attach the hook-and-loop strips, and roll the seat back trim cover down and install the first row of hog rings. 7. Attach the hook-and-loop strips, and roll the seat back trim cover down and attach the seat back lower inner trim cover J-clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Page 7815 8. Attach the seat back lower outer trim cover J-clip. 9. NOTE: RH shown, LH similar. Fold the backrest trim cover over on each side of the inboard and outboard recliner. Install the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners on the seat backrest frame. 10. Install the seat backrest. 11. Install the passenger seat and repower the SRS. Do not prove out the SRS at this time. Passenger seat 12. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Description and Operation Child Seat: Description and Operation ATTACHING SAFETY SEATS WITH TETHER STRAPS Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Refer to Child Safety Seat Tether Anchor - Second Row and Child Safety Seat Tether Anchor Third Row in the removal and installation portion or the Owner's Literature for usage information. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7823 View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7824 View 151-21 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit C216C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7827 Air Bag Control Module: Diagrams Restraints Control Module C310A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7828 C310B (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 7829 C310B (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 7830 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 7831 - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: When installing a new RCM, it is necessary to carry out programmable module installation (PMI). System failure may occur if PMI is not performed. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Carry out the steps necessary to prepare for programmable module installation (PMI). 2. Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 7832 5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle may cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. - CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 7833 7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9. Carry out the steps necessary to complete PMI. 10. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7837 C3159 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7838 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM) Removal and Installation NOTE: - The air bag warning indicator 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 shown, manual seat similar. - Seat is removed for clarity. 1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant classification system module (OCSM) electrical connector. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 7839 out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7845 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7846 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7847 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7848 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7849 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7850 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7851 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7852 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7853 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7854 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7855 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7856 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 7857 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Child Safety Seat Tether Anchors The second row outboard child safety seat tether anchors for a 5-passenger vehicle are located directly behind the seat, attached to the floor pan protruding from the carpet. Either of the tether anchors for a 5-passenger vehicle located near the back hatch door can be used for the second row center child safety seat tether anchor. There are also 2 child safety seat tether anchors/cargo tie downs located in the scuff plate at the back edge of the door. The 3 second row seats of a 7-passenger vehicle have child safety seat tether anchors that are located directly behind the second row seats attached to the floor pan, protruding from the carpet. The 2 third row child safety seat tether anchors are located directly behind the seat near the back hatch door. If the child safety seat tether anchors were in use during a collision, inspect and install new anchors as necessary. Return the vehicle structure to its original production configuration. Lower Anchors and Tethers for Children (LATCH) The 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 seat cushion frame. The attachment points protrude from the biteline between the seat cushion and seat backrest at the second row outboard seating positions. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Second Row CHILD SAFETY SEAT TETHER ANCHOR - SECOND ROW Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7864 - Second row bucket seats shown, others similar. - Carpet removed for clarity. 1. Remove the bolt(s) and tether anchor(s). - To install, tighten to 40 Nm (30 lb-ft). 2. NOTE: Sealant must be applied to the tether anchor bolts when installed. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7865 Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Third Row CHILD SAFETY SEAT TETHER ANCHOR - THIRD ROW Part 1 Part 2 Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7866 - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the liftgate scuff plate trim panel. 2. Remove the tether anchor bolt(s) and tether anchor(s). - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: Sealant must be applied to the tether anchor bolts when installed. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward, removing 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, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Page 7870 Seat Belt Buckle: Testing and Inspection FUNCTIONAL TEST - BUCKLE AND TONGUE The safety belt buckle and tongue assembly must operate freely during the latching and unlatching function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion). 1. Verify the following during the latching sequence: - Tongue insertion is not hindered by excessive effort. - A "click" is heard when the buckle latches the tongue. 2. Verify the system integrity by forcefully pulling on the belt webbing. 3. Unlatch the belt by fully depressing the buckle release button and allowing the belt to release and retract. 4. Verify the following during the unlatching process: - Push-button depression does not require excessive effort. - Tongue can be removed easily from the buckle. - Repeat the above steps 3 times. 5. If the inspection reveals an obvious concern(s) that can be readily identified, install a new safety belt buckle or safety belt retractor assembly as required. Do not attempt to carry out any repair on the buckle and tongue assembly. If a concern still exists with either component, a new safety belt buckle or safety belt retractor assembly must also be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle Seat Belt Buckle: Service and Repair Safety Belt Buckle Safety Belt Buckle - Second Row, Bucket SAFETY BELT BUCKLE - SECOND ROW, BUCKET Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle. - To install, tighten to 47 Nm (35 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7873 3. NOTE: Sealant must be applied to the safety belt buckle bolt when installed. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, Center and RH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, BENCH Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Seat cushion removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7874 1 Remove the 2 bolts and dual safety belt buckle. To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7875 NOTE: Seat is removed from the vehicle for clarity. 1. Remove the 2 bolts and dual safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, LH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, BENCH Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7876 1. Remove the 40 percent seat from the vehicle. 2. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 3. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, LH, 60/40, E-Z Entry SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, E-Z ENTRY Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7877 After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Tilt the seat forward. 2. Remove the 2 screws and inboard side shield. 3. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 4. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Safety Belt Buckle - Third Row SAFETY BELT BUCKLE - THIRD ROW Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7878 After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Power seat shown, manual seat similar. 1. Remove the RH third row seat. 2. Remove the nut and dual safety belt buckle assembly. - To install, tighten to 75 Nm (55 lb-ft). 3. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7879 Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER Removal and Installation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle > Page 7880 After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator 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. - LH shown, RH similar. All seats NOTE: If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. 1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3. Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner. - To install, tighten to 36 Nm (27 lb-ft). 6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test All seats 9. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 7885 View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 7888 C3066 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation SAFETY BELT EXTENSION ASSEMBLY In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use an extension to change the fit of the shoulder belt across the torso. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. NOTE: Inspect the D-ring cover for damage. If the cover is damage or does not remain attached, install a new D-ring cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 7895 Remove the D-ring cover. 2. Remove the bolt and D-ring. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the upper B-pillar trim panel. 4. Lower the shoulder safety belt height adjuster to the most downward position. 5. Remove the bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. 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. 7. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators or the Owner's Literature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators or the Owner's Literature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation Safety Belt Adaptive Load Limiting Retractor This vehicle is equipped with a driver and front passenger adaptive load limiting retractors. Adaptive load limiting retractors are pyrotechnic devices integrated to the driver and front passenger safety belt retractor assemblies. Adaptive load limiting retractors work in conjunction with the safety belt buckle pretensioners to control the tension of the driver and front passenger safety belts. The restraints control module (RCM) monitors the readiness of the adaptive load limiting retractor. The RCM uses this information and all other information provided by the restraints system to determine what action to be taken. Dual Locking Mode Retractors NOTE: When installing a dual locking mode retractor, the retractor should be checked to make sure it is not in the automatic locking retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, 3-point retractor systems, except the driver position, are equipped with the dual locking mode system. The emergency locking retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child safety seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. 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 an occupant's chest. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Page 7905 Seat Belt Retractor: Testing and Inspection Functional Test - Retractor The safety belt retractor assembly must be freely operational for extraction and retraction of the safety belt webbing between full extension and in-vehicle stowed positions. 1. Extract and retract the safety belt between the full extension and stowed positions. 2. Verify the retractor operates without excessive effort or binding. 3. Install a new safety belt retractor and buckle if no obvious concerns are noticed and the complaint has been verified. Functional Test - Automatic Locking Retractor WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Position the seat back into the full up position. 2. Position the height adjuster (if equipped) in the full down or up position. 3. Latch the seat belt buckle and tongue assembly. 4. Pull the shoulder belt out until the automatic locking retractor (ALR) feature is activated. 5. Release the shoulder belt and allow it to retract until it stops. 6. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new safety belt assembly. 7. Unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. 8. Pull the shoulder belt to verify the retractor assembly has converted automatically out of the ALR mode. If the shoulder belt remains locked in the stowed position, install a new safety belt retractor assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7908 - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraint 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. - LH shown, RH similar. 1. If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. 2. Depower the SRS. 3. Remove the safety belt anchor cover from the side of the seat. 4. Remove the bolt and safety belt anchor. - To install, tighten to 40 Nm (30 lb-ft). 5. NOTE: If the D-ring cover is damaged or does not remain attached, install a new D-ring cover. Remove the D-ring cover. 6. Remove the bolt and D-ring. - To install, tighten to 48 Nm (35 lb-ft). 7. Remove the upper and lower B-pillar trim panels. 8. Remove the secondary safety belt guide. 9. Disconnect the electrical connector. 10. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 11. To install, reverse the removal procedure. 12. Repower the SRS. 13. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7909 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, Bench SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, BENCH Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7910 1. Remove the second row, 40 percent seat. 2. Remove the bolt and safety belt anchor. - To install, tighten to 75 Nm (55 lb-ft). 3. NOTE: LH shown, RH similar. Remove the 4 screws and position aside the latch covers. 4. Remove the safety belt guide cover. 5. Release the J-clip at the bottom of the seat backrest. 6. Remove all the staples in the backrest support panel. 7. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. Invert the seat backrest trim cover and position aside. 8. Position aside the backrest foam pad. 9. Remove the safety belt retractor cover. 10. Remove the bolt and safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 11. To install, reverse the removal procedure. 12. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7911 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, E-Z Entry SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, E-Z ENTRY Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7912 - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Seat is removed and exploded for clarity. 1. Fold the seat and tilt to the E-Z entry position. 2. Remove the 3 screws and inboard recliner outer cover side shield. 3. Remove the bolt and safety belt anchor. - To install, tighten to 55 Nm (41 lb-ft). 4. Release the backrest trim cover retainers. 5. Remove the safety belt bezel. 6. NOTE: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Invert the backrest trim cover. 7. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips. 8. Remove the pin-type retainer and safety belt retractor cover and insulator. 9. Remove the bolt and safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 10. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7913 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Outboard SAFETY BELT RETRACTOR - SECOND ROW, OUTBOARD Explorer/Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7914 Explorer Sport Trac Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7915 - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Explorer/Mountaineer and Explorer Sport Trac with 60/40 bench seat 1. Remove the appropriate 60 percent or 40 percent bench seat. Explorer Sport Trac 2. Remove the rear trim panels. Explorer/Mountaineer with 60/40 E-Z entry seat 3. Tilt the headrest to the E-Z entry position. 4. Fold the appropriate seat and tilt forward to the E-Z entry position. Explorer/Mountaineer with 60/40 E-Z entry and bench seat 5. Remove the upper C-trim pillar panel. 6. Position the rear quarter trim panel aside to access the safety belt retractor. All vehicles 7. Remove the bolt and safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 8. Remove the bolt and D-ring. - 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). 10. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7916 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row SAFETY BELT RETRACTOR - THIRD ROW Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7917 - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear quarter trim panel. 2. Remove the bolt and D-ring. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the bolt and safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner C323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7922 C2351 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7923 C303 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7924 C3201 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7925 C3202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 7926 Seat Belt Tensioner: Description and Operation SAFETY BELT BUCKLE AND PRETENSIONER The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward, removing 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, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 7927 Seat Belt Tensioner: Service and Repair SAFETY BELT BUCKLE AND PRETENSIONER Removal and Installation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 7928 outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator 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. - LH shown, RH similar. All seats NOTE: If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. 1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3. Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner. - To install, tighten to 36 Nm (27 lb-ft). 6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test All seats 9. Check the active restraint system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 7932 C356 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor Impact Sensor: Locations Forward Crash Sensor View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7938 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7939 View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7940 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7941 Impact Sensor: Locations Side Impact Sensor View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7942 View 151-23 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7943 View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7944 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7945 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 7946 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor Impact Sensor: Diagrams Forward Crash Sensor C1465 C1466 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 7949 Impact Sensor: Diagrams Side Impact Sensor C567A C644A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 7950 C3248 C3249 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7953 - 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. Depower the SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7954 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint (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. - RH shown, LH similar. - The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7955 5. Position aside the lower C-pillar trim panel. - Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the C-pillar side impact sensor. 6. NOTE: - Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts from the side impact sensor and bracket assembly. - To install, tighten to 12 Nm (9 lb-ft). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7956 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the 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. - Driver side shown, passenger side similar. 1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. NOTE: - Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7957 Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 7962 View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 7965 C3066 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Seat Pressure Sensor, Left > Page 7970 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left C3291 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Seat Pressure Sensor, Left > Page 7973 C3292 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7974 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification sensor (OCS) system is standard equipment on all front passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7975 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7976 Part 2 Removal WARNING: - The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. - Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: - The air bag warning indicator 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 perform the diagnostic procedure again. - Outboard shown, inboard similar. 1. Remove the passenger seat. 2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then, using a suitable tool, release the tab and disconnect the OCS rail electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7977 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7978 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: - If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. - To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 7979 - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat. Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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 shown, manual seat similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Note the position of the seat position sensor locating tab for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Page 7983 Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 7987 C356 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7993 Accessory Delay Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Antenna: Service and Repair Antenna ANTENNA Removal and Installation 1. NOTE: To access the antenna cable-to-antenna lead-in cable connection, lower the glove compartment door. Disconnect the antenna cable from the antenna lead-in cable and release the pin-type retainers. 2. Remove the RH cowl side trim panel and the RH front door scuff plate trim panel. 3. Remove the antenna mast and the antenna mast stanchion. 4. Remove the RH fender splash shield. 5. Release the antenna cable grommet. 6. Remove the antenna cable bracket bolt and the antenna cable assembly. - To install, tighten to 8 Nm (71 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7998 Antenna: Service and Repair Antenna - Satellite Radio ANTENNA - SATELLITE RADIO Removal and Installation 1. Remove the RH A-pillar trim panel. 2. Remove the 3 screws, the RH sun visor retaining clip, and the RH sun visor. - If equipped, disconnect the electrical connector. 3. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical connector. 4. NOTE: Remove the satellite antenna and pigtail through the mounting opening in the roof panel. Remove the satellite antenna. - Disconnect the electrical connector. - Loosen the antenna bolt. To install, tighten to 5 Nm (44 lb-in). - Compress the tabs and release the satellite antenna from the roof panel. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 7999 Antenna: Service and Repair Antenna Cable - Satellite Radio ANTENNA CABLE - SATELLITE RADIO Removal and Installation 1. Remove the RH A-pillar trim panel. 2. Disconnect the satellite antenna electrical connector. - Separate the satellite radio antenna cable pin-type retainers from the A-pillar and instrument panel. 3. Lower the glove compartment. - Open the glove compartment door. - Press the tabs inward and lower the glove compartment. 4. Disconnect the satellite radio antenna cable from the satellite radio receiver. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 8000 Antenna: Service and Repair Antenna Lead-In Cable ANTENNA LEAD-IN CABLE Removal and Installation 1. Remove the audio control module (ACM). 2. Lower the glove compartment door. 3. NOTE: Release the pin-type retainers. Disconnect the antenna lead-in cable connection and remove the antenna lead-in cable. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna > Page 8001 Antenna: Service and Repair Global Positioning System (GPS) Antenna GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation NOTE: This procedure is the same as the satellite radio antenna procedure, as a combination satellite radio/GPS is utilized for vehicles with navigation. 1. Remove the RH A-pillar trim panel. 2. Remove the 3 screws, the RH sun visor retaining clip, and the RH sun visor. - If equipped, disconnect the electrical connector. 3. Lower the front of the headliner enough to gain access to the GPS antenna electrical connector. 4. NOTE: Remove the GPS antenna and pigtail through the mounting opening in the roof panel. Remove the GPS antenna. Disconnect the electrical connector. - Loosen the antenna bolt. To install, tighten to 5 Nm (44 lb-in). - Compress the tabs and release the GPS antenna from the roof panel. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 column opening cover. 2. Remove the ignition lock cylinder. 3. Remove the 3 screws and the lower steering column shroud. 4. Remove the PATS transceiver. 1 Release the 2 tabs. 2 Disconnect the electrical connector. 5. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be programmed into the instrument cluster (IC) again. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Page 8006 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams C2007 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8014 C500 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8015 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal entry codes can be associated with up to two memory seat/adjustable pedal settings. 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases all the stored customer codes. The existing codes do not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6 to indicate which of the 3 personal entry code positions is to be programmed. 5. The door locks lock and unlock to confirm the new code is programmed. 6. To program an additional personal entry code, repeat Steps 2 through 4. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8016 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Position the front window glass to the full down position. 2. Position the door glass top run aside to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar trim panel. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8025 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8026 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8027 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8033 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8034 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8035 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. See: Body and Frame/Locks/Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of 6 RKE transmitters have been programmed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8038 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Autolock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it. 6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly and then sounds a second time with a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Autolock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK button 1 time to command the module to toggle the autolock/relock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock has been toggled. Auto-Unlock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it. 6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled, the horn chirps twice. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Auto-Unlock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the module to toggle the auto-unlock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the auto-unlock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that auto-unlock has been toggled. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8039 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming STEPPED UNLOCK PROGRAMMING 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the remote keyless entry (RKE) transmitter simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change. 2. Repeat STEP 1 to enable/disable the stepped unlocking feature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the configuration for driver 1 or driver 2. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8042 Keyless Entry Transmitter: Service and Repair Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the set button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8052 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8053 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8054 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8055 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8056 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8057 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8058 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8059 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8060 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8065 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8066 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8067 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8068 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8069 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8070 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8071 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8072 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8073 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8074 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8075 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8081 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8082 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8083 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8084 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8085 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8086 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8087 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8088 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8089 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8094 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8095 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8096 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8097 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8098 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8099 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8100 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8101 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8102 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8103 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8104 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8117 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8118 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8123 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8124 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8134 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8135 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8140 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8141 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Audio Control Module View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Audio Control Module > Page 8144 View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) C3342 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8147 C3342 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8148 Communications Control Module: Diagrams Audio Control Module C290A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8149 C290B C290C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Page 8150 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - When installing a new navigation audio control module (ACM), remove the navigation DVD before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. NOTE: Module configuration is only required if a new ACM is being installed. Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module Configuration) to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors and the antenna lead-in cable(s). 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8155 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8156 View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8157 Parking Assist Control Module: Diagrams C3267 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8158 C4014 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8159 C4226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8160 Parking Assist Control Module: Service and Repair Parking Aid Module Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8161 Explorer Sport Trac Removal and Installation Mountaineer 1. Remove the RH quarter trim panel. Explorer Sport Trac 2. Remove the cab rear trim panel. Mountaineer 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Remove the parking aid speaker push pins. - Remove the parking aid speaker. Explorer Sport Trac 4. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. All vehicles 5. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8162 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 8166 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8169 C4011 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8170 C4010 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8171 C4012 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8172 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s). 3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams Parking Assist Warning Indicator: Diagrams C3268 C4015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 8179 C253 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 8180 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The message center functions are controlled by the SELECT/RESET button on base instrument clusters (IC), and by the message center switches on high series instrument clusters (IC). The base series instrument cluster message center has a display format of 2 lines x 12 characters, and the high series instrument cluster message center has a display format of 4 lines x 12 characters. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Refer to the Owner's Literature for operating instructions. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. 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 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 (IC). 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Trouble Code Descriptions/Information and Message Center 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 NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The message center information can be selected through the SELECT/RESET button (base cluster) and by the INFO, SETUP, and RESET buttons (high series cluster). The message center is an integral part of the instrument cluster (IC) that receives and acts upon much of the same information that is input and used to operate the instrument cluster (IC) gauges, informational indicators, and warning indicators. The message center, located in the center of the instrument cluster (IC) is a liquid crystal display (LCD). 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 (IC) indications. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8183 For example, when the LH front door is opened, the message center displays the message DRIVER DOOR AJAR along with the door ajar warning indicator. This allows the message center to be a more informative supplement to the instrument cluster (IC) gauges and indicators. 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 (IC) Network Messages NOTE: Whenever a network 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 (IC) and throughout the vehicle. Once a DTC is set in the instrument cluster (IC), 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 (IC) uses input messages from other modules to control the gauges, informational indicators, warning indicators and message center displays 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 for the driver door ajar off status for less than 5 seconds and the door ajar indicator was on, 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 (IC) 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 to Instrument Cluster 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. Message Center Features The message center provides the following features: Information displays - Setup displays - System check messages - Warning messages Information Displays (Base Instrument Cluster [IC]) The information displays are non-timed modes. The selected mode remains on until the driver presses the SELECT/RESET switch to change the mode, or until it is overridden by another mode. The information display modes are: - Odometer/trip odometer, compass headings - Outside air temperature display (if equipped) - Distance to empty - Average fuel economy - Setup menu Information Displays (High Series Instrument Cluster [IC]) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display - Distance to empty - Average fuel economy - Instantaneous fuel economy - Fuel used - Trip elapsed drive time - Blank Setup Displays (Base Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SELECT/RESET button to scroll through the SETUP MENU display sequence. If the SELECT/RESET button is not pressed within 4 seconds, the message center returns to the INFO MENU. The setup display modes are: System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Parking aid (if equipped) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8184 - Oil life reset and start value Setup Displays (High Series Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SETUP button for the following displays: System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Running boards (if equipped) - Easy entry/exit seat (if equipped) - Parking aid (if equipped) - Compass zone - Compass calibration - Oil life reset and start value System Check Displays Selecting this function from the SETUP MENU causes the message center to cycle through each of the systems being monitored. For each of the monitored systems, the message center indicates either an OK message or a warning message for 2 seconds. For base instrument clusters (IC), the SELECT/RESET button must be held down after pressing the SELECT/RESET button to cycle the messages through each of the systems being monitored. For high series instrument clusters (IC), pressing the RESET control switch cycles the message center through each of the systems being monitored. The system check report is as follows: OIL LIFE - CHARGING SYSTEM - WASHER FLUID - DOOR AJAR - EXTERIOR LAMPS - BRAKE FLUID LEVEL - PARK BRAKE - FUEL LEVEL AND DISTANCE TO EMPTY (high series instrument cluster [IC]) - MILES TO EMPTY (base instrument cluster [IC]) - FUEL LEVEL LOW (base instrument cluster [IC]) System Warnings The system warnings 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 more warning messages. This allows the operator full functionality of the message center after acknowledgement of the warning message by pressing the reset button and clearing the message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected. - They reappear on the display 10 minutes from the reset if the condition has not been corrected. - They do not reappear until an ignition OFF-ON cycle has been completed. - They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle. The warning displays that cannot be reset are: DOOR AJAR The warning messages that reoccur after 10 minutes are: FUEL LEVEL LOW - PARK BRAKE ENGAGED - CHECK BRAKE SYSTEM The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: CHECK PARK AID (if equipped) - BRAKE FLUID LEVEL LOW - CHECK HEADLAMP - CHECK HIGHBEAM - CHECK TURN LAMP - WASHER FLUID LOW LEVEL - OIL CHANGE REQUIRED - ENGINE OIL CHANGE SOON The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR - CLEAR OBJECTS BY PASS SEAT - CHECK CHARGING SYSTEM - LOW TIRE PRESSURE Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8185 - TIRE MONITOR FAULT - TIRE SENSOR FAULT The message center displays messages that indicate a system state during the operation of the four wheel drive (4WD) system. The displayed warning messages are as follows: FOR 4X4 LOW STOP VEHICLE (if equipped) - FOR 4X4 LOW SHIFT TO N (if equipped) - TO EXIT 4X4 LOW STOP VEHICLE (if equipped) - TO EXIT 4X4 LOW SHIFT TO N (if equipped) The message center displays 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 TIRES - TIRES TRAINED - TIRES NOT TRAINED The message center displays messages that indicate a system state during repair procedures related to the compass display. The displayed warning messages are as follows: COMPASS ZONE XX (base instrument cluster [IC]) - RESET FOR ZONE SETTING (high series instrument cluster [IC]) - ZONE XX RESET TO CHANGE (high series instrument cluster [IC]) - ZONE XX IS SET - PRESS RESET FOR CALIBRATION (high series instrument cluster [IC]) - CIRCLE SLOW TO CALIBRATE (base instrument cluster [IC]) - CIRCLE SLOWLY TO CALIBRATE (high series instrument cluster [IC]) - CALIBRATION COMPLETED The message center displays 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: HOLD RESET IF NEW OIL - OIL LIFE SET TO 100% - OIL LIFE START VALUE SET TO XXX% (high series instrument cluster [IC]) - OIL LIFE SET TO XXX% (base instrument cluster [IC]) Outside Air Temperature Sensor (Instrument Cluster [IC] Without Electronic Automatic Temperature Control [EATC]) The instrument cluster (IC) receives the outside air temperature data from the outside air temperature sensor. This data is then displayed on the message center. The outside air temperature sensor is located on the radiator core support behind the front grill assembly and is fastened with a pin-type retainer. If equipped with EATC, the outside air temperature data from the outside air temperature sensor is displayed in the heating ventilation air conditioning (HVAC) module. Refer to Heating and Air Conditioning for the outside air temperature display in the EATC. Compass The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message center display. The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the vehicle may also affect compass accuracy. The compass sensor module is mounted behind the interior rear view mirror. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8186 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8187 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8188 Symptom Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8189 Symptom Chart (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8190 Symptom Chart (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8191 Symptom Chart (Part 6) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8192 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly (High Series Instrument Cluster [IC]) PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER [IC]) Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster (IC) through circuits CMC29 (GN/VT) and RMC32 (GN/BU). This pinpoint test is intended to diagnose the following: - Message center switch concern - Instrument cluster (IC) A1 A2 Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module communicates the vehicle direction to the instrument cluster (IC), which is displayed in the message center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to communicate to the instrument cluster (IC). - DTC B2097 (Compass Module Failure) - is a continuous memory DTC that sets in the instrument cluster (IC) if the data received from the compass module is invalid. - DTC U2013 (Compass Module is Not Responding) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) fails to receive a response from the compass module after 4 consecutive attempts. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Compass sensor module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8193 B1 B1-B3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8194 B3-B4 Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster (IC) through the compass communication data plus circuit 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. This pinpoint test is intended to diagnose the following: - Calibration - Zone setting - Vehicle magnetization - Compass sensor module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8195 C1-C2 Test D: The Message Center Switch Does Not Operate Correctly (High Series Instrument Cluster [IC]) PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER [IC]) Normal Operation The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch function to the instrument cluster (IC) message center. The message center switch is grounded through circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the instrument cluster (IC) to determine which switch is pressed. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Message center switch - Instrument cluster (IC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8196 D1-D3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8197 D3-D5 Test E: The Outside Air Temperature Display Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE CORRECTLY NOTE: The outside air temperature display is only available in base instrument clusters (IC) without electronic automatic temperature control (EATC). 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 (IC) through input circuit VH407 (YE/GN) and return circuit RMC32 (GN/BU). The instrument cluster (IC) 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 an extended period of time, or the engine temperature is cold, the instrument cluster (IC) displays the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8198 current outside air temperature as measured by the ambient air temperature sensor. When the engine has only been turned off for a short time, or if the engine is not cold, the instrument cluster (IC) 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 (IC) displays the current temperature. If the temperature is greater than the last key off temperature reading, the instrument cluster (IC) displays the last key off temperature reading until the ambient air temperature has had time to stabilize with vehicle movement. - DTC B1255 (Air Temperature External Sensor Circuit Open) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) detects an open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects an open on the outside air temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F). - DTC B1257 (Air Temperature External Sensor Circuit Short to Ground) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) detects a short to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects a short to ground on the outside air temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Ambient air temperature sensor - Instrument cluster (IC) E1-E3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8199 E3-E5 Test F: The WASHER FLUID LOW LEVEL Warning Is Inoperative PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE Normal Operation The instrument cluster (IC) is hardwired to the low washer fluid switch (part of the windshield washer reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid level is approximately 1/3 full, providing a ground to the instrument cluster (IC) through circuit GD108 (BK/VT) and displaying the WASHER FLUID LOW LEVEL warning. When the washer fluid is above the low level, the low washer fluid switch opens, removing the ground to the instrument cluster (IC), and the WASHER FLUID LOW LEVEL warning turns off. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8200 - Washer fluid level switch (part of the windshield washer reservoir) - Instrument cluster (IC) F1-F2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8201 F3-F6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8202 F6-F7 Test G: The CHECK CHARGING SYSTEM Warning Is Inoperative PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE Normal Operation The charging system warning indicator is controlled by the instrument cluster (IC) based upon data received from the PCM over the high speed controller area network (HS-CAN). This pinpoint test is intended to diagnose the following: - Charging system - Instrument cluster (IC) G1-G2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Configuration Driver/Vehicle Information Display: Service and Repair Message Center Configuration MESSAGE CENTER CONFIGURATION Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. - All message center functions are carried out using the single stem reset button in the instrument cluster. 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Configuration > Page 8205 Driver/Vehicle Information Display: Service and Repair Message Center Switch MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8206 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8215 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8216 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8221 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8222 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8223 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8224 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8225 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8226 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8227 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8228 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8229 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8230 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8231 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8237 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8238 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8243 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8244 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8245 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8246 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8247 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8248 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8249 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8250 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8251 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8252 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8253 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8258 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8259 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8265 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8266 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams C3312 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 8271 Auxiliary Input / Output Jack: Service and Repair AUDIO INPUT JACK Removal and Installation 1. Remove the floor console finish panel. 2. Release the tabs and remove the audio input jack. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Locations DVD Player: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Locations > Page 8275 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Locations > Page 8276 C9029 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair Entertainment System Control Panel: Service and Repair REAR ENTERTAINMENT MODULE (RETM) Removal NOTE: Programmable module installation (PMI) only needs to be carried out if the rear entertainment module (RETM) player is being replaced. 1. Upload the RETM configuration to the scan tool. 2. NOTE: Open the RETM display. Remove the 4 screws. 3. Remove the RETM. - Pull down on the sides of the RETM to disengage the clips from the bracket. - Using a suitable tool, push the rear most U-hook forward and release the U-hooks. - Hang the RETM on the J-hooks and disconnect the electrical connector. - Remove the RETM from the J-hooks. Installation 1. Hang the RETM on the J-hooks. 2. Connect the electrical connector. 3. Remove the RETM from the J-hooks. 4. NOTE: Tilt the RETM, as necessary, to align it correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair > Page 8293 Align the left side guide pin with the left side locating hole. 5. Lift up the right side of the RETM and engage the U-hooks. 6. Install the 4 screws. 7. Push on the left and right sides of the RETM to engage the clips. 8. Download the RETM configuration from the scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8297 C928 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8298 Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The universal transmitter is an integral part of the overhead console 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Wiring, terminals or connectors - Universal transmitter - Receiver unit 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8301 Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8302 Garage Door Opener Transmitter: Pinpoint Tests PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE Normal Operation The universal transmitter is integral to the overhead console. The universal transmitter can be programmed to operate up to 3 garage doors, entry gates, security systems, and home or office lighting. Voltage is supplied from the battery saver relay in the smart junction box (SJB) to the universal transmitter through circuit CLN01 (GN/VT) and the universal transmitter is grounded on circuit GD133 (BK). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Universal transmitter - Receiver unit A1-A4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8303 A4 Continued Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8304 Garage Door Opener Transmitter: Programming and Relearning UNIVERSAL TRANSMITTER PROGRAMMING NOTE: A new battery in the hand-held transmitter may allow quicker and easier training due to a more accurate transmission of the radio frequency signal. 1. Verify the hand-held transmitter is operative. 2. Turn the key to the ON position. 3. Prepare for programming the universal transmitter by erasing all 3 channels by holding down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 4. Select 1 of the 3 universal transmitter buttons to be used for programming. 5. Hold the end of the hand-held transmitter 25-76 mm (1-3 in) away from the front surface of the universal transmitter so that the universal transmitter red light can still be seen. 6. NOTE During programming, the hand-held transmitter may automatically stop transmitting after 2 seconds, which may not be long enough to program the universal transmitter. If programming with this type of hand-held transmitter, continue to hold the button on the universal transmitter while pressing and releasing the hand-held transmitter button every 2 seconds. At the same time, press the hand-held transmitter button and the desired button on the universal transmitter until the red light on the universal transmitter flashes first slowly, and then rapidly. Release both buttons when the rapid flashing begins. 7. Firmly press and hold for 5 seconds, then release the just-trained universal transmitter button up to 2 separate times to activate the door. If after 2 separate times, the door still does not activate, press and hold the just-trained universal transmitter button and observe the indicator light. If the indicator light stays on constantly, programming is complete and the device should activate when the universal transmitter button is pressed and released. - If the indicator light blinks rapidly for 2 seconds and then turns to a constant light, follow the Training a Garage Door Opener Equipped With "Rolling Codes" procedure to complete the programming of a rolling code equipped device. Training a Garage Door Opener Equipped With "Rolling Codes" 1. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 2. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) There are 30 seconds to initiate step 3. 3. Return to the vehicle and firmly press, hold for 2 seconds and release the programmed universal transmitter button. Repeat the press/hold/release sequence a second time, and depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming process. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 8305 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8315 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8316 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8322 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8323 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8328 Memory Positioning Module: Diagrams C341A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8329 C341B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8330 C341C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8331 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8332 Part 2 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. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed (if it was replaced) it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8336 C2094 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8346 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8347 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8353 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8354 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Pedal Positioning Motor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8359 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8360 Pedal Positioning Motor: Diagrams C2003 C2159 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 8364 C2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams C466 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8369 C3041 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Compact Disc Player (CD): Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Compact Disc Player (CD): All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 8387 C2208 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair Remote Control: Service and Repair STEERING WHEEL CONTROLS 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise Speaker: Customer Interest Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 8399 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise Speaker: All Technical Service Bulletins Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 8405 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front C523 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 8408 C612 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 8409 C702 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 8410 C802 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8411 Speaker: Testing and Inspection SPEAKER WALK-AROUND TEST NOTE: To enter the speaker walk-around test or audio control module (ACM) self-diagnostic mode, the audio system must be on and in radio tuner mode. 1. To enter the speaker walk-around test, simultaneously press preset buttons 3 and 6. 2. The speaker walk-around test stops at each speaker and applies sound to each speaker for about 1-2 seconds. Each speaker is tested and displayed on the ACM in the following sequence: RF, LF, LR, RR, and SUBWOOFER. 3. To exit the speaker walk-around test, turn the key OFF, turn the audio system off, or press preset button 1 for diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 1. Remove the door trim panel. 2. Remove the 4 screws and the door speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 8414 Speaker: Service and Repair Subwoofer Speaker SUBWOOFER SPEAKER Removal and Installation 1. Remove the rear trim panel. 2. Disconnect the electrical connector. 3. Remove the 3 bolts and the subwoofer enclosure. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8420 Accessory Delay Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8433 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8434 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8439 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8440 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8450 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8451 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8456 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8457 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Audio Control Module View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Audio Control Module > Page 8460 View 151-17 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) C3342 (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8463 C3342 (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8464 Communications Control Module: Diagrams Audio Control Module C290A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8465 C290B C290C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Page 8466 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - When installing a new navigation audio control module (ACM), remove the navigation DVD before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. NOTE: Module configuration is only required if a new ACM is being installed. Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module Configuration) to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors and the antenna lead-in cable(s). 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8475 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8476 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8481 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8482 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8483 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8484 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8485 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8486 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8487 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8488 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8489 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8490 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8491 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8497 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8498 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8503 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8504 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8505 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8506 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8507 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8508 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8509 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8510 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8511 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8512 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8513 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8518 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8519 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8525 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8526 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8548 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8549 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8555 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8556 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8565 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8566 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8572 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8573 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 8579 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 8585 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8589 View 151-25 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8590 View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8591 Parking Assist Control Module: Diagrams C3267 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8592 C4014 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8593 C4226 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8594 Parking Assist Control Module: Service and Repair Parking Aid Module Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8595 Explorer Sport Trac Removal and Installation Mountaineer 1. Remove the RH quarter trim panel. Explorer Sport Trac 2. Remove the cab rear trim panel. Mountaineer 3. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Remove the parking aid speaker push pins. - Remove the parking aid speaker. Explorer Sport Trac 4. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. All vehicles 5. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8596 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Parking Assist Distance Sensor: Locations View 151-26 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 8601 View 151-27 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8604 C4011 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8605 C4010 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8606 C4012 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8607 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s). 3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8611 C2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 8615 C2208 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 8620 C239 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 Trailer Connector: Connector Views C439 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 C473 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Material Removal and Installation NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement rear trailer hitch crossmember will be bolted to the frame. All vehicles 1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring harness. Explorer/Mountaineer 4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Explorer/Mountaineer template No. 1. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8646 EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - For the inboard side use Explorer/Mountaineer template No. 2. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8647 EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - For the outboard side use Explorer/Mountaineer template No. 3. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8648 EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER Explorer Sport Trac 6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Sport Trac template No.1. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8649 SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - Use Sport Trac Template No. 2. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8650 SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - Use Sport Trac template No. 3. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8651 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer surfaces of the frame rails, making sure all mating surfaces are free of foreign material. 10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of the frame rails where bare metal is present. 11. NOTE: It may be necessary to spread apart or pull together the frame rails slightly to get the brackets to fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8652 Insert the new trailer hitch cross member assembly into the frame. 12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts. - Tighten to 235 Nm (174 lb-ft). 14. Tighten the outboard bolts. - Tighten to 235 Nm (174 lb-ft). 15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer turn lamps. The trailer parking and reversing lamps share the vehicle lighting outputs. The vehicle is supplied with wiring to support an aftermarket trailer brake control (TBC) module. The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer tow connector. Field-Effect Transistor (FET) Protection The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a customer demand of the function (switching the component on, battery saver being energized). When an excessive circuit load occurs several times, the module shuts down the output until a repair procedure is carried out. At the same time, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal until a successful on-demand self-test proves that the fault has been repaired. After the on-demand self-test has successfully completed (no on-demand DTCs present), the continuous DTC clears and the circuit function returns. Each circuit has 3 predefined levels of short circuit tolerance established in the module based on each circuits' capability. When the first or second level is reached, the continuous DTC associated with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are shorted past the third level, then B106F and B1342 set along with the associated continuous DTC. These DTCs cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer stop/turn output circuits. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched) - 17 (30A) (trailer brake control (TBC) module) - Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps) - 12 (5A) (trailer tow battery charge relay coil) - 16 (10A) (trailer reversing lamps) - 25 (15A) (trailer parking lamps) - Circuity - Trailer - SJB 4. 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. 5. NOTE: Make sure to use the latest scan tool release software. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8675 6. 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. 7. 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 PCM. 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 10. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8676 B2070 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8677 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8678 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8679 Trailer Lamps: Pinpoint Tests Test W: All The Trailer Lamps Are Inoperative PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE Normal Operation Ground for the all trailer lamps is provided through circuit RAT08 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer W1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8680 W1-W2 Test X: The Trailer Lamps Are Inoperative - Parking Lamps PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING Normal Operation When the vehicle parking lamps are on, the smart junction box (SJB) provides voltage to the trailer parking lamps through circuit CAT17 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8681 X1-X2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8682 X2-X4 Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS Normal Operation Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8683 Y1-Y3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8684 Y3-Y4 Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP Normal Operation Voltage to the LH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit CAT06 (YE). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the SJB detects a short to ground from the LH trailer stop/turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the LH trailer stop/turn lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8685 Z1-Z6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8686 Z6-Z7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8687 Z8-Z9 Tests AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN LAMP Normal Operation Voltage to the RH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit CAT09 (GN). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the SJB detects a short to ground from the RH trailer stop/turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the RH trailer stop/turn lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8688 AA1-AA6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8689 AA6-AA7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8690 AA8-AA9 Tests AB: The Trailer Lamps Are On Continuously PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE) and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively. The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer - SJB AB1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8691 AB1-AB3 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 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A) through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay switch 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer battery charge relay - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8692 AC1-AC3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8693 AC3-AC4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8694 AC5-AC6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8695 AC6 Continued Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8696 AC7-AC9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8697 AC9-AC11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8698 AC11-AC12 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 Normal Operation The trailer brake control (TBC) module is provided voltage at all times by the battery junction box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides voltage to the trailer tow connector through circuit CAT19 (BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer tow connector - Trailer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8699 AD1-AD3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8700 AD3-AD5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8701 AD6-AD8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8702 AD8-AD9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 8703 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8707 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 8711 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Trailer Connector: Connector Views C439 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 C473 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 8738 Body Control Systems: Description and Operation MODULE CONTROLLED FUNCTIONS NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The 2 multifunction electronic control modules on this vehicle are: - Driver seat module (DSM) - Smart junction box (SJB) Driver Seat Module (DSM) The driver seat module (DSM) is located under the driver seat. The DSM controls the memory functions of the memory seat positions, and the adjustable pedals. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or the remote keyless entry (RKE) transmitter. Smart Junction Box (SJB) The SJB is a combination of a multifunction control module and an interior junction box. The SJB functions control multiple systems, which include: Accessory delay - Battery saver - Exterior lighting - Heated rear window and mirrors - Horn - Illuminated entry and interior lighting - Power door locks - RKE system/keyless entry keypad - Tire pressure monitoring system (TPMS) - Warning chimes - Windshield wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview Body Control Systems: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse 14 (30A) - Smart junction box (SJB) fuse 1 (20A) - Wiring, terminals or connectors - SJB 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 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 DSM. 9. If the DTCs retrieved are related to the concern, refer to the 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/Driver Seat Module (DSM) Principles of Operation PRINCIPLES OF OPERATION The DSM controls the memory driver seat positions and the memory adjustable pedals. The DSM receives inputs from the memory set switches in order to program the 2 separate, personalized memory positions for the seats and (if equipped) the adjustable pedals. These positions can be recalled by either pressing the memory switches or by unlocking the vehicle with the remote transmitters. The DSM also receives inputs from the driver seat switch and outputs the requested command to the seats. If the vehicle has memory, the DSM will also receive inputs from the adjustable pedal switch and outputs the requested commands to the adjustable pedal motor. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or the remote keyless entry (RKE) transmitter. Refer to Locks for the remote memory activation general procedure. The DSM is on the medium speed controller area network (MS-CAN). The DSM supports intermodule and scan tool communications. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8741 - Battery junction box (BJB) fuses: 1 (50A) - 2 (50A) - 3 (50A) - Smart junction box (SJB) fuse 2 (5A) - Wiring, terminals or connectors - SJB 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 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, refer to the 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/Smart Junction Box (SJB) Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The SJB receives inputs and delivers outputs to electronically-controlled features of the vehicle. The SJB constantly monitors the systems under its control and reports a concern in the form of a DTC. The DTC can be retrieved with a scan tool through the medium speed controller area network (MS-CAN). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8742 Body Control Systems: Diagnostic Trouble Code Descriptions B106A-B1119 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8743 B111F-B1178 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8744 B1200-B1317 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8745 B1317-B1342 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8746 B1342-B1485 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8747 B1499-B1688 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8748 B1696-B1957 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8749 B1960-B2051 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8750 B2070-B2266 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8751 B229A-B2439 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8752 B2477-B2505 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8753 B2507-B2817 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8754 B287A-B2987 / C1095 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8755 C1145-C1707 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8756 C1708-C2278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8757 C2780 / P062F-P0712 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8758 P0713-P0741 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8759 P0743-P0963 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8760 P0963-P1705 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8761 P1707-P2763 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8762 P2764 / U0073-U0184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8763 U0193-U1900 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8764 U1900-U2050 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8765 U2050-U2511 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 8766 Body Control Systems: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver Seat Module (DSM) Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver Seat Module (DSM) > Page 8769 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 8774 Auxiliary Step / Running Board Module: Diagrams C4322A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 8775 C4322B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 8776 Auxiliary Step / Running Board Module: Service and Repair POWER RUNNING BOARD (PRB) MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left View 151-20 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 8781 View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left C3185 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left > Page 8784 C3186 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 8785 Auxiliary Step / Running Board Motor: Service and Repair POWER RUNNING BOARD (PRB) MOTOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: If the power running board (PRB) cannot be extracted, extend the running board by hand. Extend the PRB. 3. Remove the straps and disconnect the PRB motor electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 8786 4. Remove the wedge screw and wedge. Note orientation for reinstallation. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the 3 bolts and PRB motor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Carry out any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8793 Front Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - FRONT Exploded View Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8794 Mountaineer Removal and Installation Explorer/Explorer Sport Trac 1. Remove the headlamp assemblies. All vehicles 2. Disconnect the fog lamp electrical connectors, if equipped. 3. Disconnect the side turn signal lamp electrical connectors, if equipped. 4. Remove the front fender inner splash shield screws. 5. Remove the front fender inner splash shield pin-type retainers. 6. Remove the front fender inner splash shields. 7. Remove the 2 bolts from the bottom of the bumper cover. Explorer/Explorer Sport Trac 8. Remove the 6 grille-to-grille opening panel scrivets. NOTE: The fender clips are removed with the front fender. Use a flat-blade screwdriver to release the locking tabs from the front bumper cover. 9. Release the bumper cover-to-fender clips. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8795 Mountaineer 10. Remove the bumper cover upper screws. 11. Rotate the bottom of the front bumper cover upward. 12. Apply downward pressure to the top of the front bumper cover to release the 3 locking tabs. All vehicles 13. Remove the front bumper cover. 14. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Page 8799 Mountaineer Removal and Installation 1. Remove the front bumper cover. 2. Remove the 4 front bumper bolts. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the front bumper. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Carry out any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8805 Rear Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - REAR Exploded View Explorer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8806 Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8807 Explorer Sport Trac Removal and Installation 1. Remove the 6 rear bumper cover screws. - To install, tighten to 6 Nm (53 lb-in). 2. Remove the 6 rear bumper cover splash shield screws (3 each side). 3. Disconnect the license plate electrical connector. 4. CAUTION: To avoid damaging the rear bumper cover, do not twist the cover when removing. Remove the bumper cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8808 - Pull the outer corners outward and pull the bumper cover rearward to disengage the cover from the retaining clips. 5. Transfer the components as necessary. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Exploded View Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 8813 Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 8814 Removal and Installation 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8822 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the screw and the energy absorbing foam pad. 4. If equipped, disconnect the door lock cylinder actuating rod. 5. Open the clip and disconnect the exterior front door handle actuating rod. 6. Remove the 2 exterior front door handle nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the exterior front door handle. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE - FRONT Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Page 8826 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Remove the 3 screws and the interior front door handle. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8830 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. NOTE: Slide the foam insulating block forward to release the 2 clips. Remove the screw and the energy absorbing foam pad. 4. Release the interior door handle actuating cable locator from the door frame. 5. Disconnect the front door latch harness electrical connector and release the harness locator from the door frame. 6. Open the clip and disconnect the exterior front door handle actuating rod. 7. Release the front door push button rod from the door frame retainer. 8. If equipped, disconnect the front door lock cylinder actuating rod from the lock cylinder. 9. Remove the 3 screws and the front door latch. - To install, tighten to 12 Nm (9 lb-ft). 10. To install, reverse the removal procedure. - Lubricate the front door latch after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8834 Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8835 Removal and Installation 1. Remove the front door trim panel handle bezel cover. 2. Remove the front door trim panel handle bezel screws. 3. Remove the front door trim panel lower screws. CAUTION: To avoid damaging the front door trim panel, do not pull the bottom of the panel outward. 4. Remove the front door trim panel by lifting upward on the armrest to disengage the panel clips. 5. Disconnect the electrical connectors. 6. Disconnect the lock rod cable from the front door trim panel. 7. Disconnect the door handle conduit and cable from the front door trim panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments STRIKER ADJUSTMENT 1. Loosen the door latch striker plate screws. 2. Adjust the door latch striker plate from side-to-side or up and down as necessary. 3. Tighten the door latch striker plate screws. - Tighten to 25 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8843 Part 2 Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 8847 Part 2 Removal and Installation 1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8851 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector. 5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield. 7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement. 9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. Damage to the window regulator will occur if the holes become enlarged. The new rivets may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window glass-to-regulator rivets. 10. Secure the front door glass in the full UP position with tape. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8852 11. Disconnect the window regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the window regulator assembly. 14. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8858 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Open the clip and disconnect the exterior rear door handle actuating rod. 4. Remove the 2 nuts and the exterior rear door handle. - To install, tighten to 9 Nm (80 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE - REAR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Page 8862 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Remove the 3 interior rear door handle screws and the interior rear door handle. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8866 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Release the interior door handle actuating cable locator from the door frame. 4. Open the clip and disconnect the exterior handle actuating rod. 5. Disconnect the rear door ajar switch and rear door lock actuator electrical connectors. 6. Remove the 3 rear door latch screws. - To install, tighten to 12 Nm (9 lb-ft). 7. Release the rear door push button rod from the door frame retainer. 8. To install, reverse the removal procedure. - Lubricate the door latch after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8870 Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8871 Explorer/Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8872 Explorer Sport Trac Removal and Installation 1. Remove the rear door trim panel assist handle cover. 2. Remove the rear door trim panel assist handle screws. 3. Remove the rear door trim panel handle bezel cover. 4. Remove the rear door trim panel handle bezel screws. 5. Remove the rear door trim panel lower screw. 6. CAUTION: To avoid damaging the trim panel, do not pull the bottom of the panel outward. Remove the rear door trim panel by lifting upward on the armrest to disengage the panel clips. 7. Disconnect the electrical connectors. 8. Disconnect the rod cable from the rear door trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8873 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 8878 Part 2 Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Page 8882 Part 2 Removal and Installation 1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3. Remove the 3 window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the window regulator motor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 8886 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior moulding. 4. Remove the rear door weather shield. 5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. Damage to the window regulator will occur if the hole becomes enlarged. The new rivet may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window glass-to-regulator rivet. 6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window regulator motor electrical connector. 8. Remove the 2 rear window regulator mounting nuts. - To install, tighten to 10 Nm (89 lb-in). 9. Remove the 3 window regulator motor bracket nuts. - To install, tighten to 10 Nm (89 lb-in). 10. Remove the window regulator assembly. 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Removal and Installation NOTE: Mark the position of the hood latch prior to removing the hood latch bolts to aid positioning during installation. 1. Remove the 2 hood latch bolts. - To install, tighten to 12 Nm (9 lb-ft). 2. Disconnect the hood latch release cable from the hood latch and remove the latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 8891 - Check the latch adjustment to make sure the latch was installed and aligned correctly. - Lubricate the hood latch after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Removal and Installation 1. Remove the hood latch. 2. Remove the screw and the hood latch release handle. 3. Remove the pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch release cable assembly screw. 5. Release the hood latch release cable from the 4 cable locators and remove the cable. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 8900 View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator C4040 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 8903 C457 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Latch Actuator LIFTGATE LATCH ACTUATOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator > Page 8906 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab and remove the liftgate latch actuator. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator > Page 8907 Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Window Latch Actuator LIFTGATE WINDOW LATCH ACTUATOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator > Page 8908 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Remove the 3 screws and the liftgate window latch actuator. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 8912 C4039 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 8916 C479 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 8920 Part 2 Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate release handle actuating rod. 4. Remove the 2 liftgate release handle screws. 5. Remove the liftgate release handle. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8925 Part 2 Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate release handle actuating rod. 4. Disconnect the liftgate latch actuator and the liftgate ajar switch electrical connectors. 5. Remove the 3 liftgate latch screws and remove the latch. - To install, tighten to 12 Nm (9 lb-ft). 6. To install, reverse the removal procedure. - Lubricate the liftgate latch after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8926 Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch LIFTGATE WINDOW LATCH Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8927 Part 2 Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate window actuator and liftgate window ajar switch electrical connectors 4. Remove the 4 screws and the liftgate window latch. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. - Lubricate the liftgate window latch after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 8932 Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 8933 Removal and Installation 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 8939 Mountaineer Removal and Installation 1. Loosen the running board bolts and lower the running board to access the front fender moulding pin-type retainer. - To install, tighten to 23 Nm (17 lb-ft). 2. Remove the lower pin-type retainer from the front fender moulding. 3. Remove the 2 rear pin-type retainers from the front fender moulding. 4. Position the front fender moulding aside and remove the splash shield lower screw. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 8940 5. Remove the front splash shield screws. 6. Remove the front splash shield pin-type retainers. 7. Remove the front splash shield. 8. Remove the front fender splash shield. 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation Frame and Body Mounting The frame consists of 2 steel-channel rails, 10 crossmembers for Explorer Sport Trac or 8 crossmembers for Explorer/Mountaineer including a front crossmember, transmission support crossmember and a rear crossmember (trailer hitch). New side rails and welded crossmembers, including the trailer hitch, are not installed separately. A front frame rail repair kit is available if the front rail is to be repaired and a rear crossmember (hitch) repair kit is available if the rear crossmember or rail is to be repaired. The 1B crossmember and transmission crossmember are included in assembly to the frame but can be serviced separately. Frame-Mounted Heat Shields The frame-mounted heat shields are attached to the top of the frame and crossmembers with bolts. The body must be lifted off the frame enough for access to the bolts that attach the heat shields to the top of the frame. Structural Enhancement - Explorer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8945 Structural Enhancement - Explorer Sport Trac The purpose of these inserts is to enhance the structural rigidity of the frame in this area. Inserts cannot be repaired or installed new. CAUTION: When removing upper body mounts, enough adjacent body mount support bolts and nuts must be removed to prevent damage occurring to the vehicle. NOTE: - Body mounts must be held with a wrench on the bottom while loosening the bolt from the top. - Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. - No lubricants of any kind are to be used during body mount support installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8946 Body Support - Front End Sheet Metal Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8947 Body Support - No. 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8948 Body Support - No. 2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8949 Body Support - No. 3 (Explorer/Mountaineer ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8950 Body Support - No. 3 (Explorer Sport Trac ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8951 Body Support - No. 4 (Explorer/Mountaineer ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Cross-Member: Service and Repair Transmission Support Crossmember Transmission Support Crossmember Transmission Support Crossmember Removal and Installation 1. With the vehicle in NEUTRAL, position it on hoist. 2. Remove the 4 transfer case skid plate bolts and remove the transfer case skid plate. - To install, tighten to 15 Nm (11 lb-ft). 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 8957 - To install, tighten to 18 Nm (13 lb-ft). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (13 lb-ft). 5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove the 6 transmission crossmember lower bolts. - To install, tighten to 80 Nm (59 lb-ft). 8. NOTE: Tighten the nut side of the joint. Remove the 2 upper nuts and 2 bolts from the transmission crossmember. - To install, tighten to 143 Nm (105 lb-ft). 9. Remove the transmission crossmember. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 8958 Cross-Member: Service and Repair Crossmember - 1B Crossmember - 1B Crossmember - 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts. - To install, tighten to 103 Nm (76 lb-ft). 4. Remove the 1B crossmember. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Material Removal and Installation NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement rear trailer hitch crossmember will be bolted to the frame. All vehicles 1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring harness. Explorer/Mountaineer 4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Explorer/Mountaineer template No. 1. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8962 EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - For the inboard side use Explorer/Mountaineer template No. 2. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8963 EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - For the outboard side use Explorer/Mountaineer template No. 3. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8964 EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER Explorer Sport Trac 6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Sport Trac template No.1. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8965 SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - Use Sport Trac Template No. 2. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8966 SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - Use Sport Trac template No. 3. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8967 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer surfaces of the frame rails, making sure all mating surfaces are free of foreign material. 10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of the frame rails where bare metal is present. 11. NOTE: It may be necessary to spread apart or pull together the frame rails slightly to get the brackets to fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8968 Insert the new trailer hitch cross member assembly into the frame. 12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts. - Tighten to 235 Nm (174 lb-ft). 14. Tighten the outboard bolts. - Tighten to 235 Nm (174 lb-ft). 15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 8972 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer Interest for Grille: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling Grille: Customer Interest Body - Chrome Grille Peeling/Blistering/Wrinkling TSB 08-10-4 05/26/08 CHROME GRILLE - PEELING, BLISTERING OR WRINKLING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a peeling, blistering or wrinkling chrome grille. ACTION Follow the Service Procedure steps to correct the condition. NOTE BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND NON-WARRANTABLE CONDITIONS. SERVICE PROCEDURE Replace the grille using Work Shop Manual (WSM), Section 501-08. 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 081004A 2006-2008 Explorer, 1.2 Hrs. 2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper Cover (Do Not Use With 8200A, 17957A, 13007C) DEALER CODING CONDITION BASIC PART NO. CODE 8200 34 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grille: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling Grille: All Technical Service Bulletins Body - Chrome Grille Peeling/Blistering/Wrinkling TSB 08-10-4 05/26/08 CHROME GRILLE - PEELING, BLISTERING OR WRINKLING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a peeling, blistering or wrinkling chrome grille. ACTION Follow the Service Procedure steps to correct the condition. NOTE BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND NON-WARRANTABLE CONDITIONS. SERVICE PROCEDURE Replace the grille using Work Shop Manual (WSM), Section 501-08. 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 081004A 2006-2008 Explorer, 1.2 Hrs. 2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper Cover (Do Not Use With 8200A, 17957A, 13007C) DEALER CODING CONDITION BASIC PART NO. CODE 8200 34 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8986 Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the 2 grille-to-bumper cover screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8987 3. Remove the front bumper isolator and absorber. 1. Remove the 2 pushpins. 2. Remove the 2 nuts. 4. Remove the 4 scrivets. 5. Carefully release the 14 clips and remove the grille assembly from the bumper cover. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console Console: Service and Repair Floor Console Front FLOOR CONSOLE - FRONT Removal and Installation 1. Move the front seats to the full rearward position. 2. Remove the LH and RH front floor console rear bolts. 3. Position the front seats to the full rearward position. 4. Remove the selector lever bezel. 5. Open and lift the front floor console stowage door upward. 6. Remove the 2 front floor console finish panel screws. 7. Remove the front floor console finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8993 - Disconnect the electrical connector. 8. Disconnect the front floor console electrical connector. 9. Remove the 2 front floor console-to-instrument panel screws. 10. Remove the LH and RH front floor console pushpin retainers. 11. Remove the LH and RH front floor console extension trim panels. 12. Remove the LH and RH front floor console middle bolts. 13. Remove the front floor console. - Pull the front floor console toward the rear of the vehicle. 14. To install, reverse the removal procedures. Rear FLOOR CONSOLE - REAR Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8994 Removal and Installation NOTE: The rear floor console bracket does not need to be removed to remove the console. 1. Open the armrest and remove the storage compartment insert. 2. Remove the 4 rear floor console bolts. - To install, tighten to 9 Nm (80 lb-in). 3. CAUTION: To prevent damage to the 2 plastic guide pegs located on the bottom of the console, pull the console straight up when removing. Disconnect the electrical connector and remove the rear floor console. 4. CAUTION: To prevent damage to the 2 plastic guide pegs located on the bottom of the console, install the console straight down until the pegs are correctly seated in the holes. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8995 Console: Service and Repair Console - Overhead CONSOLE - OVERHEAD NOTE: Overhead console with garage door opener storage compartment shown, all other consoles similar. Removal and Installation 1. Remove the overhead console screw. 2. Remove the overhead console. 3. Disconnect the overhead console electrical connectors. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9001 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9002 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9003 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9004 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9005 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9006 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9007 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9008 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9009 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9010 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9011 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9012 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9013 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER Explorer/Mountaineer (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9017 Explorer/Mountaineer (Part 2) Explorer Sport Trac Removal and Installation Explorer and Mountaineer only 1. If equipped, remove the rear entertainment system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9018 Explorer Sport Trac only 2. NOTE: The headliner is removed through the rear passenger door. To facilitate removal, the front passenger seat must be removed. Remove the front passenger seat. All vehicles 3. Remove the overhead console. 4. Remove the A-pillar trim panel. 5. Position the B-pillar upper trim panel aside. Explorer and Mountaineer only 6. Remove the C-pillar trim panel. 7. Remove the D-pillar trim panel. Explorer Sport Trac 8. Position the C-pillar upper trim panel aside. All vehicles 9. Remove the gimp around the roof opening panel, if equipped. 10. Remove the 4 sun visor retainer screws. 11. Remove the sun visors. 12. Carefully lower the headliner at the corner of the sun visor location to access the electrical connector and disconnect the electrical connector. 13. Disconnect the roof opening panel, if equipped. 14. Disconnect the interior mirror electrical connector and electronic compass sensor connector, if equipped. 15. Use a thin-blade tool and carefully remove the dome lamp cover. 16. Disconnect the dome lamp electrical connectors. Explorer and Mountaineer only 17. Remove the upper air duct. - Remove the pin-type retainers. - Push down on the duct, tilt the top outward and pull upward to remove. 18. Remove the lower air duct. 19. Disconnect the electrical connector located at the C-pillar. - Release the wiring harness pin-type retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9019 20. Disconnect all the electrical connectors. All vehicles 21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar. 22. CAUTION: To prevent bending or damaging the headliner, an assistant is required to support the headliner while carrying out the remaining steps. Open the sun visor center retainer cover and remove the screw. 23. Remove the sun visor center retainer. 24. Remove the rear pin-type retainer. 25. CAUTION: To prevent damaging the garment hanger retainer, use a 3/16-inch flat-blade screwdriver to carry out this step. NOTE: The garment hanger is shown without the roof sheet metal screw 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 garment hangers. 1. Open the access door. 2. Insert the flat-blade screwdriver fully into the garment hanger slot. 3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip. Remove the plastic garment hanger. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9020 26. NOTE: The headliner is removed through the passenger rear door for Explorer Sport Trac. Remove the headliner. 27. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked Sun Visor: Customer Interest Interior - Sun Visor Mirror Cover Cracked TSB 09-2-9 02/09/09 SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008 FORD: 2007-2009 Explorer Sport Trac, Explorer MERCURY: 2007-2009 Mountaineer ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor mirror cover hinge. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace all affected sun visors with new updated parts. 2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical connector. 3. To install, reverse the removal procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090209A 2007-2009 Explorer, 0.3 Hr. Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A) 090209B 2007-2009 Explorer, 0.4 Hr. Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A) DEALER CODING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 9029 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked Sun Visor: All Technical Service Bulletins Interior - Sun Visor Mirror Cover Cracked TSB 09-2-9 02/09/09 SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008 FORD: 2007-2009 Explorer Sport Trac, Explorer MERCURY: 2007-2009 Mountaineer ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor mirror cover hinge. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace all affected sun visors with new updated parts. 2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical connector. 3. To install, reverse the removal procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090209A 2007-2009 Explorer, 0.3 Hr. Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A) 090209B 2007-2009 Explorer, 0.4 Hr. Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A) DEALER CODING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 9035 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel Trim Panel: Service and Repair Cab Rear Trim Panel CAB REAR TRIM PANEL Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9040 Explorer Sport Trac Removal and Installation 1. Position the second row seat back forward. 2. Remove the 2 screws from the storage compartment. 3. NOTE: When removing the cab rear trim panel, start in the upper left corner, moving clockwise and remove the panel from the retaining clips. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9041 Remove the rear trim panel. 4. To install, reverse the removal procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9042 Trim Panel: Service and Repair Pillar Trim A-Pillar Trim Panel A-PILLAR TRIM PANEL Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9043 Explorer Sport Trac Removal and Installation 1. Remove the 2 assist handle bolt covers. 2. Remove the 2 assist handle bolts. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the assist handle. 4. Position the door opening weatherstrip aside. 5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off the A-pillar trim panel when the panel is removed. Remove the A-pillar trim panel. 6. To install, reverse the removal procedure. B-Pillar Lower Trim Panel B-PILLAR LOWER TRIM PANEL Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9044 Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9045 Explorer Sport Trac Removal and Installation 1. Remove the front and rear door scuff plates. 2. Position the door opening weatherstrip aside. 3. Remove the B-pillar lower trim panel. 4. To install, reverse the removal procedure. B-Pillar Upper Trim Panel B-PILLAR UPPER TRIM PANEL Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9046 Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9047 Explorer Sport Trac Removal and Installation 1. Remove the B-pillar lower trim panel. 2. Remove the D-ring safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Position the door opening weatherstrip aside. 4. Remove the B-pillar upper trim panel retaining clip from the lower right corner of the panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9048 5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel. 6. To install, reverse the removal procedure. - Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring bolt. C-Pillar Upper Trim Panel C-PILLAR UPPER TRIM PANEL Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9049 Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9050 Explorer Sport Trac Removal and Installation 1. Remove the C-pillar lower trim panel. 2. Remove the roof trim panel. 3. Remove the C-pillar upper trim panel. - Route the safety belt through the upper trim panel. 4. To install, reverse the removal procedures. C-Pillar Lower Trim Panel C-PILLAR LOWER TRIM PANEL Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9051 Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9052 Explorer Sport Trac Removal and Installation 1. Remove the rear seat. 2. Remove the rear cab trim panel. 3. Remove the C-pillar lower safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Position the door opening weatherstrip aside. 5. Remove the C-pillar lower trim panel. 6. To install, reverse the removal procedure. D-Pillar Trim Panel D-PILLAR TRIM PANEL Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9053 Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9054 Explorer Sport Trac Removal and Installation Vehicles with third row seating 1. Remove the rear cargo management system. - Remove the screw. - Remove the pushpin. - Remove the system. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9055 2. Remove the D-pillar lower safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). All vehicles 3. Position the liftgate opening weatherstrip aside. 4. Remove the rear upper headliner trim panel. 5. Remove the D-pillar trim panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9056 Trim Panel: Service and Repair Cowl Side Trim Panel COWL SIDE TRIM PANEL Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9057 Explorer Sport Trac Removal and Installation All vehicles 1. Remove the front door scuff plate. Passenger side 2. Remove the cowl trim panel. Driver side 3. Remove the hood release lever. 1. Remove the screw. 2. Remove the hood release lever. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9058 4. Remove the cowl trim panel. 1. Remove the pin-type retainer. 2. Remove the cowl trim panel. All vehicles 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9059 Trim Panel: Service and Repair Quarter Trim Panel QUARTER TRIM PANEL Exploded View Explorer And Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9060 Explorer Sport Trac Removal and Installation 1. Remove the rear door scuff plate. 2. Remove the C-pillar trim panel. 3. Remove the D-pillar trim panel. 4. Remove the liftgate scuff plate trim panel. 5. Remove the luggage compartment assembly cover, if equipped. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cab Rear Trim Panel > Page 9061 6. Remove the stowage compartment doors. 7. Position the carpet aside. 8. Remove the rear quarter trim panel. 9. Disconnect the electrical connectors, if necessary. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Page 9067 Part 2 Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative 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 key code of the vehicle. 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Release the front door push button rod from the door frame retainer. 4. Remove the exterior front door handle nut (rear). - To install, tighten to 9 Nm (80 lb-in). 5. Remove the door lock cylinder. - Disconnect the front door lock cylinder actuating rod. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 9072 C500 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 9073 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal entry codes can be associated with up to two memory seat/adjustable pedal settings. 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases all the stored customer codes. The existing codes do not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6 to indicate which of the 3 personal entry code positions is to be programmed. 5. The door locks lock and unlock to confirm the new code is programmed. 6. To program an additional personal entry code, repeat Steps 2 through 4. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 9074 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Position the front window glass to the full down position. 2. Position the door glass top run aside to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar trim panel. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9083 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9084 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9085 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9091 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9092 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 9093 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9099 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9100 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9101 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9107 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9108 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 9109 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. See: Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of 6 RKE transmitters have been programmed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9112 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Autolock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it. 6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly and then sounds a second time with a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Autolock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK button 1 time to command the module to toggle the autolock/relock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock has been toggled. Auto-Unlock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it. 6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled, the horn chirps twice. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Auto-Unlock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the module to toggle the auto-unlock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the auto-unlock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that auto-unlock has been toggled. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9113 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming STEPPED UNLOCK PROGRAMMING 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the remote keyless entry (RKE) transmitter simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change. 2. Repeat STEP 1 to enable/disable the stepped unlocking feature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the configuration for driver 1 or driver 2. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation > Page 9116 Keyless Entry Transmitter: Service and Repair Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the set button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 9122 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 9123 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 9124 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side C525 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 9127 C603 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 9128 C704 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 9129 C804 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator Power Door Lock Actuator: Service and Repair Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 9132 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch and the front door lock actuator electrical connectors. 3. Release the locking tab and remove the front door lock actuator. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 9133 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 9134 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab and remove the rear door lock actuator. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 9139 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 9142 C605 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9143 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9144 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9145 - Release the 4 retaining tabs. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9151 Memory Positioning Module: Diagrams C341A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9152 C341B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9153 C341C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9154 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9155 Part 2 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. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed (if it was replaced) it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9159 C2094 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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: RH shown, LH similar. 1. Remove the exterior mirror glass. 2. Remove the exterior mirror motor screws. 3. Disconnect the exterior mirror motor electrical connectors. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Page 9163 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9167 C527 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9168 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9169 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9170 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes VEHICLE CERTIFICATION (VC) CODES Vehicle Certification (VC) Label Locator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9176 The VC label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes GVWR information. If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit the VIN to their respective regional office. The regional office will submit a web form to the assembly plant for the replacement label. Once the label has been printed, a representative from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9177 Exterior Paint Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary body color. The second set of characters (if applicable) identify the vehicle accent or 2-tone body color. All colors are base coat/clear coat. Primary Exterior Color Codes DX - Dark Blue Pearl - Explorer/Explorer Sport Trac - G2 - Redfire - Explorer/Mountaineer/Explorer Sport Trac - HH - Dark Cherry - Explorer/Mountaineer/Explorer Sport Trac - HS - Earth Pearl - Mountaineer/Explorer Sport Trac - JP - Silver Birch Metallic - Explorer/Mountaineer/Explorer Sport Trac - NL - Orange Frost - Explorer/Explorer Sport Trac - PV - White Chocolate (tri-coat) - Explorer/Mountaineer - UA - Ebony - Explorer/Mountaineer/Explorer Sport Trac - WS - White Suede - Explorer/Mountaineer/Explorer Sport Trac - ZY - Silver Vapor - Explorer/Mountaineer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9178 Wheelbase - 114 - 2,895.6 mm (114 in) - Explorer/Mountaineer - 131 - 3,327.4 mm (131 in) - Explorer Sport Trac Interior Trim Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9179 Interior trim codes are listed as a 2-part code. The first character identifies the interior trim type. The second character identifies the interior trim color. Interior Trim Type 3 - Perforated leather seats - Mountaineer - 4 - Leather with heated driver seat - Mountaineer - 8 - Embossed leather with suede insert seats - Mountaineer - I - Leather with power, heated driver and passenger seats- Explorer - R - Value cloth seats - Explorer - S - Premium cloth with power driver seat - Explorer/Mountaineer - T - Leather with power, heated driver seat and memory- Explorer/Explorer Sport Trac - U - Tracks cloth bucket seats - Explorer Sport Trac - V - Leather with power driver seat - Explorer - W - Tracks cloth bucket seats with power driver seat - Explorer Sport Trac - W - Leather trim with suede inserts and power driver seat - Explorer - X - Leather trim with suede inserts and power/heated/memory driver seat - Explorer - Z - Leather with power/heated/memory driver seat - Explorer Interior Trim Color C - Camel - Explorer/Mountaineer/Explorer Sport Trac - W - Charcoal Black - Explorer/Mountaineer/Explorer Sport Trac Tape/Paint Stripe Tape and paint stripe codes do not apply. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9180 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION (VC) CODES Vehicle Certification (VC) Label Locator Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9181 The VC label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes GVWR information. If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit the VIN to their respective regional office. The regional office will submit a web form to the assembly plant for the replacement label. Once the label has been printed, a representative from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9186 Memory Positioning Module: Diagrams C341A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9187 C341B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9188 C341C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9189 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9190 Part 2 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. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed (if it was replaced) it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9195 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9196 Power Seat Relay: Locations Third Row Folding Seat Relay, Right View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9197 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 9200 C4184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9203 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9204 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9205 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations View 151-24 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 9209 Auxiliary Step / Running Board Module: Diagrams C4322A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 9210 C4322B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 9211 Auxiliary Step / Running Board Module: Service and Repair POWER RUNNING BOARD (PRB) MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 9215 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 9216 C921 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 9220 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 9226 Part 2 Removal and Installation CAUTION: The roof opening panel motor contains ceramic magnets that may fail at any time if cracked. Any roof opening panel motor that has been dropped onto a hard surface during removal or installation should be replaced with a new motor. NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning 1. NOTE: Make sure that the roof opening panel glass is in the CLOSED position before removal. Remove the overhead console. 2. Disconnect the roof opening panel electrical connectors. 3. Remove the 3 roof opening panel motor screws. - To install, tighten to 3 Nm (27 lb-in). 4. NOTE: - When installing the roof opening panel motor, it may be necessary to turn the roof opening panel motor slightly to engage the drive splines. - Anytime a roof opening panel motor is removed, the cables/mechanisms can experience free-play movement. It is important that the cables/mechanisms do not move. They are timed to be parallel with each other. Remove the roof opening panel motor. 5. To install, reverse the removal procedure. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 9230 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 9231 Sunroof / Moonroof Switch: Diagrams C912 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 9232 C9001 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 9233 C9038 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9236 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window Motor Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9237 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium Overhead Console Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 9238 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 TROUGH ASSEMBLY Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Page 9242 Part 2 Removal and Installation 1. Remove the roof opening panel glass. 2. Remove the trough assembly. - Pull the trough assembly arms outward to release the trough assembly guide arm pins from the roof opening panel frame to remove. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Page 9246 Part 2 Removal and Installation 1. Move roof opening panel to full OPEN position. 2. Remove the air deflector. - Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in). - Remove the air deflector from the roof opening panel frame. 3. To install, reverse the removal procedure. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 9250 Part 2 Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning 1. Remove the headliner. 2. Remove the 2 retaining screws and the upper console bracket. 3. Disconnect the roof opening panel motor electrical connector. 4. Disconnect the 4 roof opening panel drain hoses from the corners of the roof opening panel frame. 5. Remove the entertainment center support bracket (if equipped). - Remove the 7 bolts. - Remove the support bracket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 9251 CAUTION: To avoid damage to the roof opening panel frame, be sure to support the roof opening panel frame when removing the frame bolts. 6. Remove the 10 roof opening panel frame bolts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the roof opening panel frame. 8. To install, reverse the removal procedure. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 9255 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 9256 C921 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass ROOF OPENING PANEL GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 9261 Part 2 Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning 1. Open the roof opening panel to the VENT position. 2. Remove the 4 roof opening panel glass screws. - To install, tighten to 4 Nm (35 lb-in). 3. From the outside of the vehicle, remove the roof opening panel glass assembly. 4. To install, reverse the removal procedure. - If installing a new roof opening panel glass seal, use care around the corners to make sure of a correct seal to the roof opening panel glass. - Check for correct alignment of the roof opening panel. For additional information, refer to Roof Opening Panel Alignment. See: Adjustments - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization. See: Testing and Inspection/Programming and Relearning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 9262 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield ROOF OPENING PANEL SHIELD Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 9263 Part 2 Removal and Installation 1. Remove the roof opening panel glass. 2. Remove the trough. - Pull the trough assembly arms outward to release the trough assembly guide arm pins from the roof opening panel frame to remove. 3. Remove the air deflector. - Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in). - Remove the air deflector. 4. Slide the roof opening panel shield forward halfway. 5. Disengage the roof opening panel shield guide feet. 1 Push the roof opening panel shield toward one side of the vehicle. 2 Lift the front portion of the roof opening panel shield upward to disengage the guide feet. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 9264 6. Slide the roof opening panel shield forward and release the rear guide feet. 7. NOTE: The roof opening panel shield guide feet can be serviced separately from the roof opening panel shield. If necessary, new roof opening panel shield guide feet may be installed at this time. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Description and Operation Child Seat: Description and Operation ATTACHING SAFETY SEATS WITH TETHER STRAPS Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Refer to Child Safety Seat Tether Anchor - Second Row and Child Safety Seat Tether Anchor Third Row in the removal and installation portion or the Owner's Literature for usage information. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9273 Memory Positioning Module: Diagrams C341A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9274 C341B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9275 C341C Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9276 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9277 Part 2 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. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed (if it was replaced) it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9281 C2094 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly Power Seat Motor: Locations Power Seat Motor Assembly View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly > Page 9286 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly > Page 9287 Power Seat Motor: Locations Third Row Folding Seat Motor View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly > Page 9288 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly > Page 9289 View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor C3187 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 9292 Power Seat Motor: Diagrams Power Seat Motor Assembly C353 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 9293 C357 C3015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 9294 Power Seat Motor: Diagrams Third Row Folding Seat Motor C4181 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 9295 C4182 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9296 Power Seat Motor: Service and Repair SEAT RECLINER MOTOR Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9297 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9298 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9299 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9300 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9301 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal NOTE: The air bag warning indicator 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 seat. 2. Remove the front seat backrest. 3. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 5. Remove the one-way push clip on the side of the inboard power recliner. Slide the recliner shaft out from the outboard side of the seat enough to clear the inboard recliner and power recline motor. 6. Disconnect the electrical connector, remove the screw and the power recline motor. Installation Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 9302 1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed. Install the recliner motor in the following sequence. 1 Position the recliner shaft through the recliner motor and inboard recliner. 2 Install a new one-way push clip onto the recliner shaft at the inboard power recliner. 3 Turn the recliner motor so the recliner motor mounting hole lines up with the screw hole in the inboard power recliner. 4 Install the recliner motor bolt. 5 Connect the recliner motor electrical connector. 2. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 3. Position the backrest trim cover to the inboard and outboard recliners and install the plastic rivets. 4. Install the front seat backrest. 5. Install the front seat. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 9307 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 9308 Power Seat Relay: Locations Third Row Folding Seat Relay, Right View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 9309 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 9312 C4184 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9315 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9316 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9317 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch Power Seat Switch: Locations Third Row Folding Seat Switch View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9322 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9323 View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9324 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9325 Power Seat Switch: Locations Power Seat Switch View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9326 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch Power Seat Switch: Diagrams Power Seat Switch C352 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9329 C3016 C355 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9330 Power Seat Switch: Diagrams Third Row Folding Seat Switch C4179 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9331 C4180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9334 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9335 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9336 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 9337 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 SEAT BACKREST - FRONT Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9342 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9343 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9344 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9345 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9346 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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 shown, passenger similar. All seats 1. Remove the front seat. 2. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. Make sure the lumbar is completely relaxed before removing the handle. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9347 7 Separate the cushion trim cover elastic strap from the cushion side shield. If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Release the cushion trim cover rear J-clips. 1 Release the cushion trim cover rear inboard J-clip from the inboard recliner. 2 For a driver seat or passenger seat equipped with heat, release the cushion trim cover rear J-clips. 4. Release the cushion trim cover inboard J-clip. 5. Remove the safety belt buckle and pretensioner electrical connector cover. 6. Remove the 2 safety belt buckle and pretensioner nuts. - To install, tighten to 36 Nm (27 lb-ft). 7. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle switch electrical connector. - Remove the safety belt buckle and pretensioner. Seat with manual lumbar 8. Release the cushion trim cover front J-clip. Raise the cushion foam pad and release the lumbar cable pin-type retainer. 9. Remove the 2 screws and separate the manual lumbar control from the cushion frame. 10. Remove the cable from the manual lumbar control. Driver seat with power recline 11. Disconnect the backrest power feed electrical connector and route out the wire harness. - Release any wire harness retainers. Passenger seat with heat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9348 12. Disconnect the backrest heated seat mat electrical connector and route out the wire harness. - Release any wire harness retainers. All seats 13. Release the pin-type retainers, disconnect and route out the side air bag module electrical connector and wire harness. 14. NOTE: Driver shown, passenger similar. Release the side air bag wire harness pin-type retainers across the back of the cushion frame. 15. Remove the 4 recliner-to-cushion frame bolts and remove the backrest assembly. - Route out the manual lumbar cable and any wire harnesses (if equipped). - To install, tighten to 55 Nm (41 lb-ft). 16. To install, reverse the removal procedure. 17. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. 40 Percent E-Z Entry SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9349 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9350 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9351 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9352 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9353 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9354 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9355 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9356 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9357 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9358 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9359 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9360 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9361 Second Row, 40 Percent Bench, Cushion Removal 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover to expose the 2 inboard and 2 outboard recliner-to-backrest frame bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9362 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 4. Release the kneeling mechanism cable from the backrest frame. 5. Remove the 2 inboard and 2 outboard recliner-to-backrest frame bolts and remove the backrest assembly. Installation 1. Remove 3 screws, recliner handle and outboard recliner outer cover. 2. Remove 2 screws and the inboard recliner outer cover. 3. WARNING: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. Position the inboard recliner pin to the recliner stop. The recliner pin must contact the inboard recliner outer plate (stop). 4. WARNING: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. - If the inboard recliner is not positioned to the recliner stop (or any upright position), when the outboard recliner is positioned to the recliner stop and the release strap is let go of, the recliners will not lock in place. Pull the release strap at the outboard recliner and position the outboard recliner pin to contact the recliner stop. Let go of the release strap and the inboard and outboard recliners will lock in place. Each recliner pin must contact the recliner outer plate (stop). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9363 5. Position the backrest assembly to the inboard and outboard recliners and hand start the 2 inboard and 2 outboard recliner-to-backrest frame bolts. 6. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Install the recliner-to-backrest frame bolts in the following sequence: 1 Install the inboard recliner-to-backrest frame upper bolt. Tighten to 55 Nm (41 lb-ft). 2. Install the inboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 3. Install the outboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 4. Install the outboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 7. Position the kneeling mechanism release handle and cable back through the backrest frame and backrest trim cover openings. - Attach the kneeling mechanism release cable to the backrest frame. 8. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 9. Position the kneeling mechanism release handle to the backrest opening and push in, engaging the clips. 10. Route the outboard recliner release strap before installing the outboard recliner outer cover. 11. Install the outboard recliner outer cover. - Position the outboard recliner outer cover. - Route the release strap through the cover. - Install the 2 screws. - Install the recliner handle. - Install the screw. 12. Position the inboard recliner outer cover and install the 2 screws. 13. Install the second row, 40 percent E-Z entry seat into the vehicle. 14. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. 60 Percent, E-Z Entry SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9364 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9365 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9366 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9367 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9368 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9369 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9370 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9371 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9372 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9373 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9374 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9375 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9376 Second Row, 40 Percent Bench, Cushion Removal 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover to expose the 2 inboard and 2 outboard recliner-to-backrest frame bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9377 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 4. Release the kneeling mechanism cable from the backrest frame. 5. Remove 2 screws and the inboard recliner outer cover. 6. Remove the safety belt anchor bolt and separate the safety belt anchor from the inboard recliner. 7. Remove the 2 inboard and 2 outboard recliner-to-backrest frame bolts and remove the backrest assembly. Installation 1. Remove 3 screws, recliner handle and outboard recliner outer cover. 2. WARNING: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. NOTE: An assistant will be necessary for this procedure. - If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. - If both of the recliners are not locked in place simultaneously, the recliners will not lock in position. Simultaneously pull the release strap at the outboard recliner and position the inboard and outboard recliner pins to the recliner stops. Let go of the release strap and the inboard and outboard recliners will lock in place. Each recliner pin must contact the recliner outer plate (stop). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9378 3. Position the backrest assembly to the inboard and outboard recliners and hand start the 2 inboard and 2 outboard recliner-to-backrest frame bolts. 4. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Install the recliner-to-backrest frame bolts in the following sequence. 1 Install the inboard recliner-to-backrest frame upper bolt. Tighten to 55 Nm (41 lb-ft). 2. Install the inboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 3. Install the outboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 4. Install the outboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 5. Position the kneeling mechanism release handle and cable back through the backrest frame and backrest trim cover openings. - Attach the kneeling mechanism release cable to the backrest frame. 6. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 7. Position the kneeling mechanism release handle to the backrest opening and push in, engaging the clips. 8. Route the outboard recliner release strap before installing the outboard recliner outer cover. 9. Position the outboard recliner outer cover, recliner handle and install the 3 screws. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9379 10. CAUTION: Make sure the safety belt webbing is not twisted prior to installation or damage may occur. Position the safety belt anchor to the inboard recliner and install the safety belt anchor bolt. Tighten to 55 Nm (41 lb-ft). 11. Position the inboard recliner outer cover and install the 2 screws. - Make sure the kneeling mechanism release cable pivot is still positioned on the inboard recliner and the recliner pin is through the cable pivot before installing the inboard recliner outer cover. 12. Install the second row, 60 percent E-Z entry seat into the vehicle. 13. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. 40 Percent, Bench SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9380 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9381 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9382 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9383 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9384 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9385 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9386 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9387 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9388 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9389 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9390 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9391 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9392 Second Row, 40 Percent Bench, Cushion Removal 1. Release the seat backrest J-clip. 2. Remove all the staples holding the backrest trim cover to the backrest support panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9393 3. Invert the seat backrest trim cover and foam pad to access the latch cover screws. 4. Remove the 4 screws and the 2 covers. Detach the seat backrest material attachment from both of the latch covers. 5. Remove the 2 backrest support panel lower screws and detach the latch cable. Position the cable out from between the backrest frame and backrest support panel. 6. Remove the 4 backrest pivot bolts. 7. Remove the 40 percent backrest. Installation 1. Position the backrest to the latch. The cable is to be routed in front of the spring. 2. NOTE: When installing the backrest to the cushion, make sure the latch cover does not come in contact with the latch cable conduit or end fitting. The cable is to move freely after assembly. The cable is to pass between the backrest frame and the backrest support at the 2 points shown. 3. Install the 4 backrest pivot bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the 2 backrest support panel lower screws. 5. CAUTION: When installing the backrest to the cushion, make sure the latch cover does not come in contact with the latch cable conduit or end fitting. Position the 2 covers and install the 4 screws. Attach the material attachments to both of the latch covers. 6. Roll the seat backrest trim cover and foam pad back down into position. 7. Position the trim cover and install staples in the backrest support panel. 8. Attach the seat backrest J-clip. 60 Percent, Bench Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9394 SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9395 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9396 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9397 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9398 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9399 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9400 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9401 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9402 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9403 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9404 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9405 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9406 Second Row, 40 Percent Bench, Cushion Removal 1. Remove the safety belt anchor bolt. 2. Release the seat backrest J-clip. 3. Remove all the staples holding the backrest trim cover to the backrest support panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9407 4. Invert the seat backrest trim cover and reposition the foam pad to access the latch cover screws and latch cable. 5. Remove the 4 screws and the 2 covers. Detach the seat backrest material attachment from both of the latch covers. 6. Remove the 2 backrest support panel lower screws and detach the latch cable. Position the cable out from between the backrest frame and backrest support panel. 7. Remove the outboard upper pivot latch bolt. 8. Remove the 4 backrest pivot bolts. 9. Remove the 60 percent backrest. Installation 1. Position the backrest to the latch. The cable is to be routed in front of the spring. 2. CAUTION: The cable is to move freely after assembly. The cable is to pass between the backrest frame and the backrest support at the 2 points shown. 3. Install the 4 backrest pivot bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the outboard pivot latch bolt. - Tighten to 40 Nm (30 lb-ft). 5. Install the 2 backrest support panel lower screws. 6. Attach the material to both of the latch covers. Position the 2 covers and install the 4 screws. 7. Roll the seat backrest trim cover and foam pad back down into position. 8. Position the trim cover and install staples in the backrest support panel. 9. Attach the seat backrest J-clip. 10. Position the safety belt anchor and install the bolt. - Tighten to 75 Nm (55 lb-ft). Bucket Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9408 SEAT BACKREST - SECOND ROW, BUCKET Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9409 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9410 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9411 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9412 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9413 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9414 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9415 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9416 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9417 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9418 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9419 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9420 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Release all of the seat backrest J-clips. Slightly raise the backrest trim cover. 2. Remove all of the staples in the backrest trim cover. 3. Pull the seat backrest material up and remove the 4 backrest bolts. Remove the backrest assembly. - To install, tighten to 23 Nm (17 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9421 Seat Back: Overhaul Seat Backrest - Front SEAT BACKREST - FRONT Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9422 Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9423 Front Seat Backrest (Part 2) Disassembly WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTE: If a side air bag deployment took place a new backrest foam pad, backrest trim cover and side air bag module must be installed. A new backrest frame should be installed if necessary. - The air bag warning indicator illuminates when the restraint 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. - The manual recliners and power recliners are serviced as part of the backrest frame. All seats 1. Remove the front seat. 2. Remove the front seat backrest. 3. Remove the head restraint. 1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head restraint. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9424 Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 6. Remove the first row of hog rings. 7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings. 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame. 9. Remove the backrest trim cover. Heated seat 10. For power driver seat, disconnect the backrest heated seat mat electrical connector. - If necessary, remove the backrest heated seat mat from the backrest foam pad. All seats 11. Separate the backrest foam pad from the backrest frame. 12. NOTE: Note the side air bag module wire harness routing for assembly. Release the side air bag module wire harness pin-type retainers, remove the bolts and the side air bag module with wire harness. Seat with manual lumbar 13. Release the 2 manual lumbar spring clips from the backrest frame and remove the manual lumbar. Seat with power lumbar 14. Remove the power lumbar adjust assembly in the following sequence. 1 Disconnect the power lumbar adjust assembly motor electrical connector. 2 Release the 2 power lumbar adjust assembly lower pin-type retainers to the backrest frame. 3 Slide the power lumbar adjust assembly rods out of the backrest frame at the top and remove the power lumbar adjust assembly. Seat with power recline 15. Remove a one-way push clip from the recliner shaft and remove the recliner shaft. 16. Disconnect the electrical connector, remove the screw and the power recline motor. Assembly Seat with power recline Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9425 1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed. Install the recliner motor. Position the recliner shaft through the inboard power recliner, power recline motor and outboard recliner. Slight turning of the recliner shaft may be necessary. - Install a new one-way push clip at each end of the recliner shaft. - Turn the power recline motor so the mounting hole lines up with the bolt hole in the inboard power recliner. - Install the power recline motor bolt. - Connect the power recline motor electrical connector. Seat with power lumbar 2. Install the power lumbar adjust assembly. - Slide the power lumbar adjust assembly rods into the backrest frame holes at the top. - Attach the 2 power lumbar adjust assembly lower pin-type retainers to the backrest frame. - Connect the power lumbar adjust assembly motor electrical connector. Seat with manual lumbar 3. Attach the 2 manual lumbar spring clips to the backrest frame. All seats 4. WARNING: - Before installing the seat side air bag module/deployment chute assembly: Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. - Inspect the seat side air bag module cavity in the seat backrest foam pad for any foreign material. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Failure to follow this instruction may result in wiring harness damage. Align the holes of the side air bag module bracket to the U-nuts on the backrest frame. Install new U-nuts if installing a new side air bag module. 5. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the backrest frame. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9426 6. Install the side air bag module bolts, route the wire harness as noted during disassembly and install the side air bag module wire harness pin-type retainers. Tighten to 10 Nm (89 lb-in). Heated seat 7. If necessary, install the backrest heated seat mat. - For driver seats with power recline, connect the backrest heated seat mat electrical connector. All seats 8. Position the backrest foam pad around the backrest frame. 9. Position the backrest trim cover to the backrest frame and foam pad. 10. Roll the backrest trim cover down, attach the hook-and-loop strips and install the second row of hog rings. 11. Roll the backrest trim cover down, attach the hook-and-loop strips and install the first row of hog rings. 12. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 13. Position the backrest trim cover to the inboard and outboard recliners and install the plastic rivets. 14. NOTE: The head restraint guides are not interchangeable. Install the head restraint guides. 15. Install the head restraint. 16. Install the front seat backrest. 17. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9427 40 Percent E-Z Entry SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY Second Row, 40 Percent E-Z Entry Backrest Disassembly and Assembly 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. 2. Remove the second row, 40 percent E-Z entry seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9428 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips, invert the trim cover as high as it will go. 5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the 2 head restraint guides. 6. Remove the backrest trim cover. 7. Separate the backrest foam pad from the backrest frame. 8. To assemble, reverse the disassembly procedure. 60 Percent, E-Z Entry SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9429 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9430 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Disassembly and Assembly 1. Remove the second row, 60 percent E-Z entry seat. 2. Remove the second row, 60 percent E-Z entry seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 4. Remove the safety belt bezel. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips and invert the trim cover as high as it will go. 6. From between the backrest foam pad and the backrest frame, reach up pinch the ends together and remove the 2 head restraint guides. 7. Route out the safety belt and remove the backrest trim cover. 8. Remove the backrest foam pad from the backrest frame. 9. Remove the safety belt retractor cover. - Remove the pin-type retainer. - Release the rear of the safety belt retractor cover from the backrest frame. - Route out the safety belt and remove the safety belt retractor cover. 10. Remove the bolt, safety belt retractor and insulator. - To install, tighten to 75 Nm (55 lb-ft). - If necessary, remove the safety belt retractor insulator. 11. To assemble, reverse the disassembly procedure. 40 Percent, Bench SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9431 Disassembly and Assembly 1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row, 40 percent seat backrest. 4. Remove the 3 screws and the latch cover. 5. Remove the bolt and the safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 6. Remove the head restraint. 7. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9432 - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 8. CAUTION: Use care when separating the seat back 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 fasteners. Remove the seat backrest trim cover. 9. Remove the backrest foam pad. 10. Remove the 2 outboard lower latch bolts. - To install, tighten to 40 Nm (30 lb-ft). 11. Remove the 2 inboard lower latch bolts. - To install, tighten to 40 Nm (30 lb-ft). 12. CAUTION: Do not detach the latch cable from the seat latches. The latch assembly is synchronized; if disassembled, the latch assembly may not operate correctly. Remove the latch assembly. Do not separate or disassemble the latch assembly components. 13. To assemble, reverse the disassembly procedure. 60 Percent, Bench SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9433 Disassembly and Assembly 1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row, 60 percent seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9434 4. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 5. Pull at the bottom and remove the safety belt guide cover. 6. CAUTION: Use care when separating the seat back 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 fasteners, invert the backrest trim cover and remove the hog rings. Remove the backrest trim cover. Feed the safety belt out through the backrest trim cover. 7. Remove the backrest foam pad. 8. Remove the safety belt retractor cover. 9. Remove the bolt and the safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 10. To assemble, reverse the disassembly procedure. Bucket SEAT BACKREST - SECOND ROW, BUCKET Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9435 Disassembly and Assembly 1. Remove the second row, 40 percent bucket seat backrest. 2. Remove the head restraint. 3. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the backrest trim cover hook-and-loop fasteners, remove 2 rows of hog rings and invert the backrest trim cover as high as it will go. 4. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 5. Remove the backrest trim cover. 6. Remove the backrest foam pad from the backrest frame. 7. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front Seat Cover: Service and Repair Seat Backrest Cover - Front SEAT BACKREST COVER - FRONT Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9440 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9441 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9442 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9443 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9444 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator 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 front seat. 2. Remove the front seat backrest. 3. Remove the head restraint. 1 Using an appropriate tool, push in the hole while lifting up and release the head restraint from the head restraint guide. 2 Push in on the head restraint guide release tab and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9445 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 6. Remove the first row of hog rings. 7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings. 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame. 9. Remove the backrest trim cover. 10. To install, reverse the removal procedure. 11. Install the front seat backrest. 12. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9446 Seat Cover: Service and Repair Seat Cushion Cover - Front SEAT CUSHION COVER - FRONT Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9447 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9448 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9449 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9450 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9451 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation NOTE: - The air bag warning indicator 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 front seat. 2. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. 7 Separate the cushion trim cover elastic strap from the cushion side shield. If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Release all the cushion trim cover-to-cushion frame retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9452 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. Release the hook-and-loop strips, remove the hog rings and remove the cushion trim cover from the cushion foam pad. 5. To install, reverse the removal procedure. 6. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9453 Seat Cover: Service and Repair Seat Backrest Cover - Second Row 40 Percent E-Z Entry SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9454 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9455 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9456 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9457 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9458 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9459 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9460 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9461 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9462 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9463 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9464 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9465 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9466 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the trim cover. 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out, separating the kneeling mechanism release handle from the backrest frame. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips and invert the trim cover as high as it will go. Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the head restraint guides. 6. Remove the backrest trim cover. 7. To install, reverse the removal procedure. 60 Percent E-Z Entry SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9467 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9468 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9469 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9470 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9471 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9472 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9473 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9474 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9475 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9476 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9477 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9478 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9479 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9480 2. Remove 2 screws and the inboard recliner outer cover. 3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Failure to follow this instruction may result in incorrect operation of the safety belt retractor. Remove the safety belt anchor bolt and separate safety belt anchor from the inboard recliner. To install, tighten to 55 Nm (41 lb-ft). 4. Remove the safety belt bezel. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover. 6. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 7. Release the hook-and-loop strips and invert the trim cover as high as it will go. - Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 8. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the 2 head restraint guides. 9. Route out the safety belt and remove the backrest trim cover. 10. To install, reverse the removal procedure. 40 Percent, Bench SEAT BACKREST COVER - SECOND ROW, 40 PERCENT, BENCH Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9481 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9482 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9483 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9484 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9485 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9486 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9487 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9488 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9489 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9490 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9491 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9492 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9493 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the head restraint. 2. Release the seat backrest J-clip. 3. Remove all the staples holding the backrest trim cover to the backrest support panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9494 4. Invert the seat backrest trim cover and foam pad to access the head restraint sleeve. 5. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. Remove the seat backrest trim cover. 7. To install, reverse the removal procedure. 60 Percent, Bench SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, BENCH Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9495 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9496 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9497 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9498 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9499 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9500 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9501 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9502 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9503 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9504 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9505 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9506 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9507 Second Row, 40 Percent Bench, Cushion Removal and Installation All vehicles 1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9508 3. Remove the safety belt anchor bolt. - To install, tighten to 75 Nm (55 lb-ft). 4. Pull out at the bottom and remove the safety belt guide cover. Sport Trac vehicles 5. Remove the 4 screws and the upper latch cover. All vehicles 6. Remove the screws and the upper latch cover. 7. Release the backrest trim cover J-clip. 8. Remove all the staples in the backrest support panel. 9. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners, invert the backrest trim cover and remove the hog rings. 10. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 11. Separate the hook-and-loop fasteners. Remove the backrest trim cover. - Feed the safety belt out through the backrest trim cover. 12. To install, reverse the removal procedure. Bucket SEAT BACKREST COVER - SECOND ROW, BUCKET Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9509 Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9510 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9511 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9512 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9513 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9514 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9515 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9516 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9517 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9518 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9519 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9520 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9521 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the head restraint. 2 CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Release the backrest trim cover lower J-clip, separate the hook-and-loop fasteners, remove 2 rows of hog rings and invert the backrest trim cover as high as it will go. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9522 3. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 4. Remove the seat backrest trim cover. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9523 Seat Cover: Service and Repair Seat Cushion Cover - Second Row 40 Percent E-Z Entry SEAT CUSHION COVER - SECOND ROW, 40 PERCENT E-Z ENTRY Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9524 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9525 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9526 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9527 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9528 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9529 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9530 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9531 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9532 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9533 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9534 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9535 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover retainers and pin-type retainers. 3. 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. Release the hook-and-loop strips and remove the cushion trim cover from the cushion foam pad. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9536 4. To install, reverse the removal procedure. 60 Percent, E-Z Entry SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9537 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9538 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9539 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9540 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9541 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9542 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9543 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9544 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9545 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9546 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9547 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9548 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover retainers and pin-type retainers. 3. 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. Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9549 4. To install, reverse the removal procedure. - After installation, make sure the LATCH and safety belt buckles are accessible to the occupants. 40 Percent, Bench SEAT CUSHION COVER - SECOND ROW, 40 PERCENT, BENCH Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9550 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9551 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9552 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9553 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9554 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9555 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9556 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9557 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9558 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9559 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9560 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9561 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the second row 40 percent seat of the 60/40 bench seat. 2. 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. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9562 60 Percent, Bench SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, BENCH Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9563 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9564 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9565 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9566 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9567 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9568 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9569 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9570 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9571 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9572 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9573 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9574 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. 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. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9575 Bucket SEAT CUSHION COVER - SECOND ROW, BUCKET Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9576 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9577 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9578 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9579 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9580 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9581 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9582 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9583 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9584 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9585 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9586 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9587 Second Row, 40 Percent Bench, Cushion Removal and Installation 1. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row of hog rings. 2. Release the cable from the seat riser and remove the cushion trim cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9588 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose Seat Cushion: Customer Interest Interior - Outside Seat Cushion Shield is Loose TSB 07-25-10 12/24/07 LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before 7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent the outside cushion shield from losing retention to the seat base. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect for a retention bracket. (Figure 1) a. If retention bracket is present do not continue with this TSB. b. If no retention bracket is present proceed to Step 2. 2. Position the driver and passenger seats rearward. 3. Install the new retention bracket over the seat base wire support. (Figure 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page 9597 4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and attach the cushion side shield. (Figure 2) NOTE DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE, AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072510A 2006-2008 Explorer, 0.2 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat 072510B 2006-2008 Explorer, 0.3 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats DEALER CODING CONDITION BASIC PART NO. CODE 7862900 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose Seat Cushion: All Technical Service Bulletins Interior - Outside Seat Cushion Shield is Loose TSB 07-25-10 12/24/07 LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before 7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent the outside cushion shield from losing retention to the seat base. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect for a retention bracket. (Figure 1) a. If retention bracket is present do not continue with this TSB. b. If no retention bracket is present proceed to Step 2. 2. Position the driver and passenger seats rearward. 3. Install the new retention bracket over the seat base wire support. (Figure 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page 9603 4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and attach the cushion side shield. (Figure 2) NOTE DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE, AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072510A 2006-2008 Explorer, 0.2 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat 072510B 2006-2008 Explorer, 0.3 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats DEALER CODING CONDITION BASIC PART NO. CODE 7862900 07 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front Seat Cushion: Service and Repair Seat Cushion - Front SEAT CUSHION - FRONT Special Tool(s) Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9606 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9607 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9608 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9609 Passenger Seat Cushion (Part 2) Disassembly and Assembly WARNING: - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator 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 front seat. 2. Remove the seat track. 3. Remove the front seat backrest. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9610 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips, remove the hog rings and separate the cushion trim cover from the cushion foam pad. Seat with heat 5. If necessary, remove the cushion heated seat mat and route out the wire harness through the cushion foam pad opening. All seats 6. To assemble, reverse the disassembly procedure. 7. Install the front seat backrest. 8. Install the seat track. 9. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 10. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9611 Seat Cushion: Service and Repair Seat Cushion - Second Row 40 Percent E-Z Entry SEAT CUSHION - SECOND ROW, 40 PERCENT E-Z ENTRY Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9612 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Disassembly 1. Remove the second row 40 percent E-Z entry seat from the vehicle. 2. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9613 4. NOTE: The shock should be fully extended when removing. Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock at the mounting plate and cushion frame. 5. Remove the second row 40 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner handle and outboard recliner outer cover. 7. Remove 2 screws and the inboard recliner outer cover. 8. Remove the 2 screws and the latch feet release bar. 9. Release all the cushion trim cover retainers and pin-type retainers. 10. Remove the cushion trim cover and cushion foam pad from the cushion frame. 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. Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 12. Remove 2 outboard recliner-to-cushion frame bolts and separate the outboard recliner. 13. Remove the outboard recliner inner cover. 14. Remove the outboard recliner. 1 Rotate the cable casing out of the outboard recliner. 2 NOTE: The cable ends are color coded/keyed to the levers. Rotate the cable ends out of the outboard recliner levers. 3 Remove the outboard recliner. 15. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner and outer covers. 16. Separate the cable to the kneeling mechanism inboard leg. 1 Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism inboard leg. 2 Separate the cable from the kneeling mechanism inboard leg release lever. Remove any cable casing retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9614 17. Remove 2 bolts, the spacer and the latch feet retracting link. 18. Remove the 2 screws and the 2 latch foot covers. 19. Separate the cable and casing from the outboard latch foot. Remove the cable assembly. 20. Remove the screw and separate the kneeling mechanism release cable pivot at the inboard recliner. 21. Remove the 2 screws, pull to separate and remove the kneeling mechanism outboard leg inner and outer covers. 22. Separate the cable to the kneeling mechanism outboard leg and cushion frame. 1 Turn and separate the cable casing retainer at the inboard side of the outboard kneeling mechanism leg. 2 Separate the cable from the outboard kneeling mechanism leg release lever. 3 Separate any cable casing retainers to the cushion frame and remove the cable. 23. Remove the 2 inboard recliner-to-cushion frame bolts, the safety belt buckle and separate the inboard recliner with recliner release shaft. - If necessary, separate the recliner release shaft from the inboard recliner. 24. Remove the inboard recliner inner cover. 25. Remove the cushion frame. - Remove the 2 kneeling mechanism-to-cushion frame bolts. - Remove the 2 latch feet assembly-to-cushion frame bolt. - Remove the cushion frame. 26. Using the release lever, manually release the inboard and outboard latch feet and remove the latch feet assembly. 27. Remove the 2 nuts and remove the kneeling mechanism. Assembly 1. Position the kneeling mechanism to the mounting plate and install the nuts. - Tighten to 41 Nm (30 lb-ft). 2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet to partially latch. Make sure the latch feet are completely latched. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9615 Position the latching feet assembly to the mounting plate strikers and latch the feet in place. 3. Install the cushion frame. - Position the cushion frame to the latch feet assembly and kneeling mechanism. - Install the 2 latch feet assembly-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft). - Install the 2 kneeling mechanism-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft). 4. Position the recliner release shaft onto the inboard recliner release pivot stub. 5. Position the inboard recliner and recliner release shaft to the cushion frame. - Position the inboard recliner to the cushion frame with the recliner release shaft through the cushion frame opening. - Position the safety belt buckle to the inboard recliner forward bolt hole and install the 2 inboard recliner-to-cushion frame bolts. Tighten to 55 Nm (41 lb-ft). 6. NOTE: The cable ends are color coded/keyed to the levers. Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner. 7. Position the outboard recliner release pivot stub into the recliner shaft and install the outboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9616 8. Route the outboard recliner short cable, attach the cable to the latch feet assembly outboard foot and attach the cable casing retainers. 9. Route the outboard recliner long cable, attach it to the kneeling mechanism inboard leg and attach all cable casing retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9617 10. Route the kneeling mechanism release cable, position the cable pivot at the inboard recliner and install the screw. 11. Install the cable to the kneeling mechanism outboard leg and cushion frame. - Attach the cable to the kneeling mechanism outboard leg release lever. - Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism outboard leg. - Attach any cable casing retainers. 12. Position the 2 latch foot covers and install the 2 screws. 13. Position the inner and outer covers around the kneeling mechanism outboard leg and install the 2 screws. 14. Position the inner and outer covers around the kneeling mechanism inboard leg and install the 2 screws. 15. Install the latch feet retracting link. - Position the spacer between the latch feet retracting link and inboard latch foot. - Install the bolt through the latch feet retracting link and spacer and into the inboard latch foot. - Install the latch feet retracting link bolt into the kneeling mechanism inboard leg. Tighten to 8 Nm (71 lb-in). 16. Position the inboard and outboard recliner inner covers. 17. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips. 18. Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim cover retainers and pin-type retainers. - Make sure the LATCH is accessible to the occupant. 19. Position the latch feet release bar and install the 2 screws. 20. Install the second row, 40 percent E-Z entry seat backrest. 21. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 22. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. 23. NOTE: The shock should be fully extended when installed. Position and install the shock onto the seat assembly. 24. Install the second row, 40 percent E-Z entry seat into the vehicle. 25. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. 60 Percent, E-Z Entry SEAT CUSHION - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9618 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9619 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Disassembly 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. 2. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9620 4. NOTE: The shock should be fully extended when removing. Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock from the seat assembly at each end. 5. Remove the second row 60 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner handle and outboard recliner outer cover. 7. Remove the 2 screws and the latch feet release bar. 8. Release all the cushion trim cover retainers and pin-type retainers. 9. Remove the cushion trim cover and cushion foam pad from the cushion frame. 10. 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. Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 11. Remove 2 outboard recliner-to-cushion frame bolts, pull out and separate the outboard recliner. 12. Remove the outboard recliner inner cover. 13. Remove the outboard recliner. 1 Rotate the cable casing out of the outboard recliner. 2 NOTE: The cable ends are color coded/keyed to the levers. Rotate the cable ends out of the outboard recliner levers. 3 Remove the outboard recliner. 14. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner and outer covers. 15. Remove the 2 screws, pull to separate and remove the kneeling mechanism outboard leg inner and outer covers. 16. Remove the bolt and spacer and separate the latch feet retracting link from the latch feet assembly. 17. Release the tab and slide the latch feet retracting link retainer back. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9621 18. Release the tab and remove the latch feet retracting link from the kneeling mechanism. 19. NOTE: Note the routing of the cable for installation. Separate the cable to the kneeling mechanism inboard leg and cushion frame. 1 Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism inboard leg. 2 Separate the cable from the kneeling mechanism inboard leg release lever. Remove the cable casing retainers from the cushion frame. 20. Remove the 2 screws and the 2 latch foot covers. 21. Separate the cable and casing from the outboard latch foot, cushion support springs and remove the cable assembly. 22. Through the opening in the cushion frame, remove the recliner release shaft. 23. NOTE: Note the routing of the cable for installation. Separate the kneeling mechanism cable pivot at the inboard recliner. 24. NOTE: Note the routing of the cable for installation. Remove the kneeling mechanism release handle with cable. 1 Turn and separate the cable casing retainer at the inboard side of the outboard kneeling mechanism leg. 2 Separate the cable from the outboard kneeling mechanism leg release lever. 3 Separate any cable casing retainers to the cushion frame and remove the kneeling mechanism release handle with cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9622 25. Remove the cushion frame. - Remove the cushion frame-to-kneeling mechanism bolt. - Remove the cushion frame-to-latch foot assembly bolt. - Remove the 2 inboard recliner-to-cushion frame bolts. - Remove the cushion frame. 26. Remove the 2 bolts and the safety belt buckles. 27. Remove the inboard recliner. - Remove the inboard recliner-to-kneeling mechanism bolt. - Remove the inboard recliner-to-latch feet assembly bolt. - Remove the inboard recliner. Remove the inboard recliner inner cover. 28. Using the release levers, manually release the inboard and outboard latch feet and remove the latch feet assembly from the mounting plate. 29. Remove the 2 kneeling mechanism-to-mounting plate nuts and remove the kneeling mechanism. Assembly 1. Position the kneeling mechanism to the mounting plate and install the 2 kneeling mechanism-to-mounting plate nuts. - Tighten to 41 Nm (30 lb-ft). 2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet to partially latch. Make sure the latch feet are completely latched. Position the latch feet assembly to the mounting plate strikers and latch the feet in place. 3. Install the inboard recliner inner cover. 4. Position the inboard recliner. - Position the inboard recliner to the kneeling mechanism and latch feet assembly. - Hand start the latch feet assembly-to-inboard recliner bolt. - Hand start the kneeling mechanism-to-inboard recliner bolt. 5. Position the recliner release shaft onto the inboard recliner release pivot stub. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9623 6. Position the cushion frame to the inboard recliner with the recliner release shaft through the cushion frame opening. 7. Hand start the 2 inboard recliner-to-cushion frame bolts. 8. Hand start the cushion frame-to-latch foot assembly bolt and the cushion frame-to-kneeling mechanism bolt. 9. Install the bolts. - Install the inboard recliner-to-latch feet assembly bolt. Tighten to 55 Nm (41 lb-ft). - Install the inboard recliner-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft). - Install the cushion frame-to-latch foot assembly bolt. Tighten to 55 Nm (41 lb-ft). - Install the cushion frame-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft). - Install the inboard recliner-to-cushion frame rear bolt. Tighten to 40 Nm (30 lb-ft). - Install the inboard recliner-to-cushion frame front bolt. Tighten to 40 Nm (30 lb-ft). 10. NOTE: The cable ends are color coded/keyed to the levers. Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9624 11. Install the outboard recliner inner cover. 12. NOTE: The outboard recliner inner cover has been removed for clarity. Position the outboard recliner release pivot stub into the recliner shaft and install the 2 outboard recliner-to-cushion frame bolts. Tighten to 55 Nm (41 lb-ft). 13. Install the outboard recliner short cable to the latch feet assembly outboard foot and attach all cable casing retainers. 14. Install the outboard recliner long cable to the kneeling mechanism inboard leg and attach all cable casing retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9625 15. Route the kneeling mechanism release cable, position the kneeling mechanism release cable pivot at the inboard recliner and attach all cable casing retainers. 16. Make sure the inboard recliner pin is through the cable pivot. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9626 17. Install the kneeling mechanism release cable to the kneeling mechanism outboard leg. - Attach the cable to the kneeling mechanism outboard leg release lever. - Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism outboard leg. - Attach any cable casing retainers. 18. Position the inner and outer covers around the kneeling mechanism outboard leg and install the 2 screws. 19. Position the inner and outer covers around the kneeling mechanism inboard leg and install the 2 screws. 20. Position the 2 latch foot covers and install the 2 screws. 21. Position the latch feet retracting link retainer onto the latch feet retracting link shaft. 22. Position the latch feet retracting link into the kneeling mechanism coupler engaging the retainer. - The kneeling mechanism coupler is part of the kneeling mechanism. 23. Slide the latch feet retracting link retainer back to the kneeling mechanism coupler, engaging the retainer. 24. Position the spacer between the latch feet retracting link and outboard latch foot and install the bolt. 25. Align the safety belt buckle anti-rotation tabs to the cushion frame openings and install the 2 bolts. - Tighten to 40 Nm (30 lb-ft). 26. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips. 27. Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim cover retainers and pin-type retainers. - Pull the 2 safety belt buckles through the cushion trim cover and foam pad. - Make sure the LATCH is accessible to the occupant. 28. Position the latch feet release bar and install the 2 screws. 29. Install the second row, 60 percent E-Z entry seat backrest. 30. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 31. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. 32. NOTE: The shock should be fully extended when installed. Position and install the shock onto the seat assembly. 33. Install the second row, 60 percent E-Z entry seat into the vehicle. 34. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. 40 Percent, Bench SEAT CUSHION - SECOND ROW, 40 PERCENT, BENCH Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9627 Disassembly and Assembly 1. Remove the second row 40 percent seat of the 60/40 bench seat. 2. Remove the second row, 40 percent bench seat backrest. 3. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the J-clips, separate the hook-and-loop fasteners and remove the seat cushion trim cover. 4. Remove the cushion foam pad. 5. Remove the cushion pad supports. 6. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9628 60 Percent, Bench SEAT CUSHION - SECOND ROW, 60 PERCENT, BENCH Disassembly and Assembly 1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row 60 percent bench seat backrest. - To install, tighten to 40 Nm (30 lb-ft). 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. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9629 5. Remove the cushion foam pad. 6. Remove 2 cushion pad supports. 7. To assemble, reverse the disassembly procedure. Bucket SEAT CUSHION - SECOND ROW, BUCKET Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9630 Part 2 Disassembly and Assembly NOTE: LH seat shown, RH similar. 1. Remove the second row bucket seat. 2. Remove the second row bucket seat backrest. 3. Remove the screw and the release handle. 4. Remove the 2 screws and the 2 LH latch covers. 5. Remove the 2 screws and the 2 RH latch covers. 6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row of hog rings. 7. Release the cable from the seat riser and remove the cushion trim cover. 8. Remove the seat cushion foam pad. 9. Remove the 2 lower latch cover screws and the 2 LH lower latch covers. 10. NOTE: The left and right latches with cables are one assembly and should not be separated. Remove the 4 latch bolts and the latch pivot. To install, tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 9631 11. Remove the 2 latch nuts and separate the latch assembly. - To install, tighten to 40 Nm (30 lb-ft). 12. NOTE: On assembly, route the cable as shown. Remove the riser attachment cable and the latch assembly. 13. Remove the torsion rod and the cushion pad support. 14. Remove the front spring hinge bolts, springs and seat cushion frame assembly. - To install, tighten to 23 Nm (17 lb-ft). 15. To assemble, reverse the disassembly procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Seat Heater: Connector Views C335 C365 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 C334 C364 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 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 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 9656 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9659 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9660 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9661 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9662 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9663 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9664 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation NOTE: - The air bag warning indicator 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 front seat. 2. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. 7 Separate the cushion trim cover elastic strap from the cushion side shield. 8 Remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9665 Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair SEAT LATCH STRIKER - SECOND ROW, 60 PERCENT BENCH Exploded View Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9669 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9670 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9671 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9672 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9673 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9674 Second Row, Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9675 Second Row, Bucket, Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9676 Second Row, Bucket, Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9677 Second Row, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9678 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9679 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9680 Second Row, 40 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9681 Removal and Installation 1. Fold the rear 60 percent and 40 percent seat backrests forward. 2. Remove the 2 screws from the storage compartment. 3. NOTE: When separating the cab rear trim panel, start in the upper left corner, moving clockwise and separate the panel from the retaining clips. Pull to release the clips and position the cab rear trim panel forward to access the seat latch striker. 4. Remove the 2 bolts and remove the striker. - To install, tighten to 30 Nm (22 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair Seat Track: Service and Repair SEAT TRACK Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9685 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9686 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9687 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9688 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9689 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation NOTE: - The air bag warning indicator 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 front seat. Passenger seat with failed horizontal motor 2. To remove the occupant classification sensor (OCS) rails, remove the 2 horizontal screw block bolts. This will allow the power seat tracks to move independently of each other for access to the 8 OCS rail bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9690 Passenger seat receiving a new seat track 3. Remove the inboard and outboard OCS rails. Passenger seat not receiving a new seat track 4. NOTE: Note the position and the routing of the OCS sensor wiring, connector and wiring retainers for installation. Detach the 2 OCS wiring retainers at each OCS rail. Then using a suitable tool, release the tab and disconnect the RH and LH OCS rail electrical connectors. All seats 5. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. 7 Separate the cushion trim cover elastic strap from the cushion side shield. If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. Power seat 6. Separate the seat control switch wire harness pin-type retainer from the cushion frame. Driver seat 7. Disconnect the SRS seat position sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9691 8. Driver seat with 10-way power, disconnect the backrest power feed electrical connector and route out the wire harness. - Release any wire harness retainers. Heated seat 9. NOTE: Passenger shown, driver similar. Disconnect the cushion and backrest heated seat mat electrical connectors. All seats 10. Release the pin-type retainers, disconnect and route out the side air bag module electrical connector and wire harness. 11. Remove the safety belt buckle and pretensioner electrical connector cover. 12. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle switch electrical connector. 13. Release all the cushion trim cover retainers. 14. Remove the seat cushion foam pad and cushion trim cover. 15. Remove the 4 cushion frame-to-seat track nuts and the seat track. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9692 - To install, tighten to 36 Nm (27 lb-ft). Driver seat with failed horizontal motor 16. If necessary, remove the inboard horizontal screw block bolt. This will allow the inboard power seat track to move independently so the safety belt buckle and pretensioner can be removed. All seats 17. To install, reverse the removal procedure. 18. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 19. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations > Page 9696 C366 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 9701 C2089 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9706 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9709 C605 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9710 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9711 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9712 - Release the 4 retaining tabs. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9716 C527 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9717 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9718 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9719 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch Power Seat Switch: Locations Third Row Folding Seat Switch View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9724 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9725 View 151-22 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9726 View 151-30 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9727 Power Seat Switch: Locations Power Seat Switch View 151-28 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch > Page 9728 View 151-29 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch Power Seat Switch: Diagrams Power Seat Switch C352 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9731 C3016 C355 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9732 Power Seat Switch: Diagrams Third Row Folding Seat Switch C4179 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch > Page 9733 C4180 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9736 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9737 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9738 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 9739 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9743 C4039 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 9747 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9750 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Exploded View Front Seat Backrest (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9751 Front Seat Backrest (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9752 Driver Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9753 Driver Seat Cushion (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9754 Passenger Seat Cushion (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9755 Passenger Seat Cushion (Part 2) Special Tool(s) Special Tool(s) Removal and Installation NOTE: - The air bag warning indicator 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 front seat. 2. Remove the cushion side shield in the following sequence. 1 If equipped, remove the clip and manual recline handle. 2 If equipped, pull and remove the manual lumbar control knob. 3 Remove the scrivet. 4 Release the cushion side shield front clip. 5 From under the cushion side shield, release the 3 hook retainers. 6 Pull out on the cushion side shield at the back and release the pin-type retainer. 7 Separate the cushion trim cover elastic strap from the cushion side shield. 8 Remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9756 Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9760 C2094 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations View 151-36 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9764 View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9765 Sunroof / Moonroof Switch: Diagrams C912 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9766 C9001 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9767 C9038 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9770 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window Motor Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9771 Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium Overhead Console Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 9772 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 9776 C479 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation Sound Proofing / Insulation: Description and Operation Insulation INSULATION Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators, refer to Sound Proofing / Insulation. Insulation is installed: - under the hood. - in front of the instrument panel. - over and under the tunnel. - over the front and rear floor pans. - inside the B-, C- and D-pillars. - on the wheel house/quarter panel. - on the engine side dash insulator (behind the engine-car rearward). It has heat-bondable mastic deadeners for improved noise, vibration and harshness (NVH) characteristics. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 9781 Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators Sound Deadeners and Insulators WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury. NOTICE: - Mastic is made of a combustible material and should be removed prior to carrying out welding procedures to the area. Heat zones from welding near the mastic may cause the mastic material to burn. - Corrosion protection must be restored to the area AFTER the mastic material is applied. Corrosion protection products may be wax based and loss of adhesion may occur. NOTE: - The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations. Additional insulators and sound deadeners are used beyond those indicated in the illustration. - To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be installed new with the correct service replacement component. Sound Deadeners and Insulators - Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 9782 Sound Deadeners and Insulators - Explorer/Mountaineer 1. NOTE: In applications where mastic material is applied as a pumpable material at the factory, replacement of missing or damaged mastic is acceptable in the form of cut-to-fit butyl pad(s) or pumpable mastic material(s) when carrying out repairs. Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly cleaned to make sure correct adhesion will occur. The surface should be 10°C (50°F) or greater before applying the mastic. The use of a heat gun to warm the metal surface will aid in adhesion. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate Tailgate Striker: Customer Interest Body - Rattle Noise From Tailgate TSB 07-25-2 12/24/07 TAILGATE STRIKER - NOISE/RATTLE FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport Trac LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and 2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in severe conditions such as fleet applications or repetitive rough road/off-road applications. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the tailgate striker bolt using a T50 Torx bit. 2. Replace the tailgate striker with a new striker. 3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness. 4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072502A 2004-2008 F-150, F-Super 0.2 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A) 072502B 2004-2008 F-150, F-Super 0.3 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A) DEALER CODING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate > Page 9792 CONDITION BASIC PART NO. CODE 99404A42 30 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate Tailgate Striker: All Technical Service Bulletins Body - Rattle Noise From Tailgate TSB 07-25-2 12/24/07 TAILGATE STRIKER - NOISE/RATTLE FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport Trac LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and 2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in severe conditions such as fleet applications or repetitive rough road/off-road applications. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the tailgate striker bolt using a T50 Torx bit. 2. Replace the tailgate striker with a new striker. 3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness. 4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072502A 2004-2008 F-150, F-Super 0.2 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A) 072502B 2004-2008 F-150, F-Super 0.3 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A) DEALER CODING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate > Page 9798 CONDITION BASIC PART NO. CODE 99404A42 30 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment Truck Bed Cover: Service and Repair Pickup Bed Storage Compartment Lid - Front Compartment PICKUP BED STORAGE COMPARTMENT LID - FRONT COMPARTMENT Exploded View Removal and Installation 1. Open the storage compartment lid and disconnect the compartment lid struts from the door. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment > Page 9804 2. Remove the 6 storage compartment lid nuts. - To install, tighten to 12 Nm (9 lb-ft). 3. Remove the storage compartment lid. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment > Page 9805 Truck Bed Cover: Service and Repair Pickup Bed Storage Compartment Lid - Side Compartment PICKUP BED STORAGE COMPARTMENT LID - SIDE COMPARTMENT Exploded View Removal and Installation 1. Open the compartment lid and remove the pickup bed seal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment > Page 9806 2. Remove the storage compartment door. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side Compartment Truck Bed Storage Compartment Hinge: Service and Repair Pickup Bed Storage Compartment Hinge - Side Compartment PICKUP BED STORAGE COMPARTMENT HINGE - SIDE COMPARTMENT Exploded View Removal and Installation 1. Remove the side compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side Compartment > Page 9812 2. NOTE: - The side compartment hinge is installed prior to the storage compartment seal. - The surface of the compartment lid must be thoroughly cleaned before installing the new hinge. Remove the storage compartment hinge. Remove the storage compartment seal. - Remove the storage compartment hinge. - Clean the lid surface of any residual seal material. - Scuff the seal surface area. - Apply adhesive promoter. - Apply pressure to the hinge surface with a roller and allow seal to cure before installation for one hour. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side Compartment > Page 9813 Truck Bed Storage Compartment Hinge: Service and Repair Pickup Bed Storage Compartment Hinge - Front Compartment PICKUP BED STORAGE COMPARTMENT HINGE - FRONT COMPARTMENT Exploded View Removal and Installation 1. Remove the front compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side Compartment > Page 9814 2. Remove the pickup bed. 3. Remove the front compartment lid hinge nuts from the front of the pickup bed. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front compartment lid hinge from the pickup box. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Side Compartment PICKUP BED STORAGE COMPARTMENT SEAL - SIDE COMPARTMENT Exploded View Removal and Installation 1. Remove the side compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9819 2. NOTE: The storage compartment seal is installed over the hinge assembly. Remove the storage compartment seal from the storage compartment. Remove any adhesive or residual seal material. - Clean the lid surface with a 50/50 solution of alcohol and water. - Apply adhesive promotor. - Apply seal. - Apply pressure to the seal with a roller and allow seal to cure before installation for one hour. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9820 Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Front Compartment PICKUP BED STORAGE COMPARTMENT SEAL - FRONT COMPARTMENT Exploded View Removal and Installation 1. Remove the front compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9821 2. Remove the storage compartment seal from the storage compartment. - Remove any adhesive or residual seal material. - Clean the lid surface with a 50/50 solution of alcohol and water. - Apply adhesive promotor. - Apply seal. - Apply pressure to the seal with a roller and allow seal to cure before installation for one hour. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Explorer/Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9827 Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9828 Removal and Installation 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9833 Part 2 Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9837 Part 2 Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Side Compartment PICKUP BED STORAGE COMPARTMENT SEAL - SIDE COMPARTMENT Exploded View Removal and Installation 1. Remove the side compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9842 2. NOTE: The storage compartment seal is installed over the hinge assembly. Remove the storage compartment seal from the storage compartment. Remove any adhesive or residual seal material. - Clean the lid surface with a 50/50 solution of alcohol and water. - Apply adhesive promotor. - Apply seal. - Apply pressure to the seal with a roller and allow seal to cure before installation for one hour. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9843 Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Front Compartment PICKUP BED STORAGE COMPARTMENT SEAL - FRONT COMPARTMENT Exploded View Removal and Installation 1. Remove the front compartment lid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9844 2. Remove the storage compartment seal from the storage compartment. - Remove any adhesive or residual seal material. - Clean the lid surface with a 50/50 solution of alcohol and water. - Apply adhesive promotor. - Apply seal. - Apply pressure to the seal with a roller and allow seal to cure before installation for one hour. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch Brake Switch (Cruise Control): Locations Deactivator Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9850 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9851 Brake Switch (Cruise Control): Locations Brake Pedal Position Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9852 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9855 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 9856 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 9857 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch Brake Switch (Cruise Control): Locations Deactivator Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9866 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9867 Brake Switch (Cruise Control): Locations Brake Pedal Position Switch View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9868 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9871 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 9872 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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. 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 9873 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 9881 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and Installation NOTE: - The air bag warning indicator 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. 1. Depower the SRS. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel (I/P) center finish panel. 4. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install, reverse the removal procedure. 7. Repower the SRS. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9886 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9887 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9888 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9889 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9890 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9891 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9892 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9893 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9894 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9895 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9896 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9897 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9898 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9899 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 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9900 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams C909 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing Compass: Service and Repair Vehicle Demagnetizing VEHICLE DEMAGNETIZING CAUTION: During demagnetizing, the demagnetizer coil pulls toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion 4 times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Carry out the compass zone adjustment procedure. See: Compass Zone Adjustment 3. Carry out the compass calibration adjustment procedure. See: Compass Calibration Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9906 Compass: Service and Repair Compass Zone Adjustment With Message Center COMPASS ZONE ADJUSTMENT With Message Center 1. Turn the ignition switch to the ON position. 2. From the SETUP menu, select compass zone. 3. Determine which magnetic zone you are in for your geographic location. 4. Press the RESET button until the message center display changes to show the current zone setting. 5. Press the RESET button repeatedly until the correct zone setting for your geographic location is displayed. 6. Wait 4 seconds when the correct zone is chosen. Without Message Center COMPASS ZONE ADJUSTMENT Without Message Center 1. Turn the ignition switch to the ON position. 2. Locate the reset button on top of the compass sensor located behind the mirror. 3. Determine which magnetic zone you are in for your geographic location. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9907 4. Press and hold the reset button on the compass module for approximately 4 seconds until COMPASS ZONE XX appears in the instrument cluster display. 5. Continue to press the reset button until the correct zone setting for your geographic location appears in the instrument cluster display. 6. After 4 seconds, ZONE SET appears in the instrument cluster display. The zone is updated. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9908 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 (rear window defrost, heater, A/C, map lamps, wipers, heated windshield, etc.) and make sure all doors are closed. Start the vehicle. 2. From the SETUP menu, press the SETUP button to select the compass calibration function. 3. Press the RESET button. 4. NOTE: - It will take up to 5 circles to complete the calibration. - If not calibrated within 3 minutes or if the RESET button is pressed during CIRCLE SLOWLY TO CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must start over. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CALIBRATE changes to CALIBRATION COMPLETED in the message center. 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 (rear window defrost, heater A/C, map lamps, wipers, heated windshield, etc.) and make sure all doors are closed. Start the vehicle. 2. Locate the reset button on top of the compass sensor located behind the mirror. 3. Press and hold the reset button on the compass module for approximately 8 seconds and release. 4. NOTE: - It will take up to 5 circles to complete the calibration. - If not calibrated within 3 minutes or if the reset button is pressed during CIRCLE SLOWLY TO CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must start over. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CALIBRATE changes to CALIBRATION COMPLETE in the instrument cluster display. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9914 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9915 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9916 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9917 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9918 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9919 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9920 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9921 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9922 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9923 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9924 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9925 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 9926 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Release the 2 tabs and remove the instrument panel dimmer switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Page 9930 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 9935 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 9936 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 9937 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 9938 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 9941 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 9942 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 9943 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 9944 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9947 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9948 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9949 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9950 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9951 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9952 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9953 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 9957 C253 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 9958 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The message center functions are controlled by the SELECT/RESET button on base instrument clusters (IC), and by the message center switches on high series instrument clusters (IC). The base series instrument cluster message center has a display format of 2 lines x 12 characters, and the high series instrument cluster message center has a display format of 4 lines x 12 characters. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Refer to the Owner's Literature for operating instructions. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. 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 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 (IC). 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Information and Message Center 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 NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The message center information can be selected through the SELECT/RESET button (base cluster) and by the INFO, SETUP, and RESET buttons (high series cluster). The message center is an integral part of the instrument cluster (IC) that receives and acts upon much of the same information that is input and used to operate the instrument cluster (IC) gauges, informational indicators, and warning indicators. The message center, located in the center of the instrument cluster (IC) is a liquid crystal display (LCD). 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 (IC) indications. For example, when the LH front door is opened, the message center displays the message DRIVER DOOR AJAR along with the door ajar warning Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9961 indicator. This allows the message center to be a more informative supplement to the instrument cluster (IC) gauges and indicators. 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 (IC) Network Messages NOTE: Whenever a network 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 (IC) and throughout the vehicle. Once a DTC is set in the instrument cluster (IC), 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 (IC) uses input messages from other modules to control the gauges, informational indicators, warning indicators and message center displays 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 for the driver door ajar off status for less than 5 seconds and the door ajar indicator was on, 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 (IC) 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 to Instrument Cluster 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. Message Center Features The message center provides the following features: Information displays - Setup displays - System check messages - Warning messages Information Displays (Base Instrument Cluster [IC]) The information displays are non-timed modes. The selected mode remains on until the driver presses the SELECT/RESET switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings - Outside air temperature display (if equipped) - Distance to empty - Average fuel economy - Setup menu Information Displays (High Series Instrument Cluster [IC]) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display - Distance to empty - Average fuel economy - Instantaneous fuel economy - Fuel used - Trip elapsed drive time - Blank Setup Displays (Base Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SELECT/RESET button to scroll through the SETUP MENU display sequence. If the SELECT/RESET button is not pressed within 4 seconds, the message center returns to the INFO MENU. The setup display modes are: System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Parking aid (if equipped) - Oil life reset and start value Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9962 Setup Displays (High Series Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SETUP button for the following displays: System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Running boards (if equipped) - Easy entry/exit seat (if equipped) - Parking aid (if equipped) - Compass zone - Compass calibration - Oil life reset and start value System Check Displays Selecting this function from the SETUP MENU causes the message center to cycle through each of the systems being monitored. For each of the monitored systems, the message center indicates either an OK message or a warning message for 2 seconds. For base instrument clusters (IC), the SELECT/RESET button must be held down after pressing the SELECT/RESET button to cycle the messages through each of the systems being monitored. For high series instrument clusters (IC), pressing the RESET control switch cycles the message center through each of the systems being monitored. The system check report is as follows: OIL LIFE - CHARGING SYSTEM - WASHER FLUID - DOOR AJAR - EXTERIOR LAMPS - BRAKE FLUID LEVEL - PARK BRAKE - FUEL LEVEL AND DISTANCE TO EMPTY (high series instrument cluster [IC]) - MILES TO EMPTY (base instrument cluster [IC]) - FUEL LEVEL LOW (base instrument cluster [IC]) System Warnings The system warnings 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 more warning messages. This allows the operator full functionality of the message center after acknowledgement of the warning message by pressing the reset button and clearing the message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected. - They reappear on the display 10 minutes from the reset if the condition has not been corrected. - They do not reappear until an ignition OFF-ON cycle has been completed. - They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle. The warning displays that cannot be reset are: DOOR AJAR The warning messages that reoccur after 10 minutes are: FUEL LEVEL LOW - PARK BRAKE ENGAGED - CHECK BRAKE SYSTEM The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: CHECK PARK AID (if equipped) - BRAKE FLUID LEVEL LOW - CHECK HEADLAMP - CHECK HIGHBEAM - CHECK TURN LAMP - WASHER FLUID LOW LEVEL - OIL CHANGE REQUIRED - ENGINE OIL CHANGE SOON The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR - CLEAR OBJECTS BY PASS SEAT - CHECK CHARGING SYSTEM - LOW TIRE PRESSURE - TIRE MONITOR FAULT Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9963 - TIRE SENSOR FAULT The message center displays messages that indicate a system state during the operation of the four wheel drive (4WD) system. The displayed warning messages are as follows: FOR 4X4 LOW STOP VEHICLE (if equipped) - FOR 4X4 LOW SHIFT TO N (if equipped) - TO EXIT 4X4 LOW STOP VEHICLE (if equipped) - TO EXIT 4X4 LOW SHIFT TO N (if equipped) The message center displays 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 TIRES - TIRES TRAINED - TIRES NOT TRAINED The message center displays messages that indicate a system state during repair procedures related to the compass display. The displayed warning messages are as follows: COMPASS ZONE XX (base instrument cluster [IC]) - RESET FOR ZONE SETTING (high series instrument cluster [IC]) - ZONE XX RESET TO CHANGE (high series instrument cluster [IC]) - ZONE XX IS SET - PRESS RESET FOR CALIBRATION (high series instrument cluster [IC]) - CIRCLE SLOW TO CALIBRATE (base instrument cluster [IC]) - CIRCLE SLOWLY TO CALIBRATE (high series instrument cluster [IC]) - CALIBRATION COMPLETED The message center displays 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: HOLD RESET IF NEW OIL - OIL LIFE SET TO 100% - OIL LIFE START VALUE SET TO XXX% (high series instrument cluster [IC]) - OIL LIFE SET TO XXX% (base instrument cluster [IC]) Outside Air Temperature Sensor (Instrument Cluster [IC] Without Electronic Automatic Temperature Control [EATC]) The instrument cluster (IC) receives the outside air temperature data from the outside air temperature sensor. This data is then displayed on the message center. The outside air temperature sensor is located on the radiator core support behind the front grill assembly and is fastened with a pin-type retainer. If equipped with EATC, the outside air temperature data from the outside air temperature sensor is displayed in the heating ventilation air conditioning (HVAC) module. Refer to Heating and Air Conditioning for the outside air temperature display in the EATC. Compass The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message center display. The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the vehicle may also affect compass accuracy. The compass sensor module is mounted behind the interior rear view mirror. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9964 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9965 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9966 Symptom Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9967 Symptom Chart (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9968 Symptom Chart (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9969 Symptom Chart (Part 6) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9970 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly (High Series Instrument Cluster [IC]) PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER [IC]) Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster (IC) through circuits CMC29 (GN/VT) and RMC32 (GN/BU). This pinpoint test is intended to diagnose the following: - Message center switch concern - Instrument cluster (IC) A1 A2 Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module communicates the vehicle direction to the instrument cluster (IC), which is displayed in the message center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to communicate to the instrument cluster (IC). - DTC B2097 (Compass Module Failure) - is a continuous memory DTC that sets in the instrument cluster (IC) if the data received from the compass module is invalid. - DTC U2013 (Compass Module is Not Responding) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) fails to receive a response from the compass module after 4 consecutive attempts. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Compass sensor module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9971 B1 B1-B3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9972 B3-B4 Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster (IC) through the compass communication data plus circuit 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. This pinpoint test is intended to diagnose the following: - Calibration - Zone setting - Vehicle magnetization - Compass sensor module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9973 C1-C2 Test D: The Message Center Switch Does Not Operate Correctly (High Series Instrument Cluster [IC]) PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER [IC]) Normal Operation The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch function to the instrument cluster (IC) message center. The message center switch is grounded through circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the instrument cluster (IC) to determine which switch is pressed. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Message center switch - Instrument cluster (IC) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9974 D1-D3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9975 D3-D5 Test E: The Outside Air Temperature Display Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE CORRECTLY NOTE: The outside air temperature display is only available in base instrument clusters (IC) without electronic automatic temperature control (EATC). 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 (IC) through input circuit VH407 (YE/GN) and return circuit RMC32 (GN/BU). The instrument cluster (IC) 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 an extended period of time, or the engine temperature is cold, the instrument cluster (IC) displays the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9976 current outside air temperature as measured by the ambient air temperature sensor. When the engine has only been turned off for a short time, or if the engine is not cold, the instrument cluster (IC) 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 (IC) displays the current temperature. If the temperature is greater than the last key off temperature reading, the instrument cluster (IC) displays the last key off temperature reading until the ambient air temperature has had time to stabilize with vehicle movement. - DTC B1255 (Air Temperature External Sensor Circuit Open) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) detects an open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects an open on the outside air temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F). - DTC B1257 (Air Temperature External Sensor Circuit Short to Ground) - is a continuous and on-demand DTC that sets if the instrument cluster (IC) detects a short to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects a short to ground on the outside air temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Ambient air temperature sensor - Instrument cluster (IC) E1-E3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9977 E3-E5 Test F: The WASHER FLUID LOW LEVEL Warning Is Inoperative PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE Normal Operation The instrument cluster (IC) is hardwired to the low washer fluid switch (part of the windshield washer reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid level is approximately 1/3 full, providing a ground to the instrument cluster (IC) through circuit GD108 (BK/VT) and displaying the WASHER FLUID LOW LEVEL warning. When the washer fluid is above the low level, the low washer fluid switch opens, removing the ground to the instrument cluster (IC), and the WASHER FLUID LOW LEVEL warning turns off. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9978 - Washer fluid level switch (part of the windshield washer reservoir) - Instrument cluster (IC) F1-F2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9979 F3-F6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9980 F6-F7 Test G: The CHECK CHARGING SYSTEM Warning Is Inoperative PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE Normal Operation The charging system warning indicator is controlled by the instrument cluster (IC) based upon data received from the PCM over the high speed controller area network (HS-CAN). This pinpoint test is intended to diagnose the following: - Charging system - Instrument cluster (IC) G1-G2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Configuration Driver/Vehicle Information Display: Service and Repair Message Center Configuration MESSAGE CENTER CONFIGURATION Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. - All message center functions are carried out using the single stem reset button in the instrument cluster. 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Configuration > Page 9983 Driver/Vehicle Information Display: Service and Repair Message Center Switch MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9984 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9993 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9999 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked Sun Visor: All Technical Service Bulletins Interior - Sun Visor Mirror Cover Cracked TSB 09-2-9 02/09/09 SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008 FORD: 2007-2009 Explorer Sport Trac, Explorer MERCURY: 2007-2009 Mountaineer ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor mirror cover hinge. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace all affected sun visors with new updated parts. 2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical connector. 3. To install, reverse the removal procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090209A 2007-2009 Explorer, 0.3 Hr. Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A) 090209B 2007-2009 Explorer, 0.4 Hr. Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A) DEALER CODING Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 10005 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 10011 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams C434A C434B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 10035 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 10036 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 10037 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 10038 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 10039 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the safety canopy and cause serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10045 battery ground cable. Connect the battery ground cable. 4. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10046 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 eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. - 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. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10047 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10048 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10049 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim panel. 17. Disconnect the passenger side safety canopy module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10050 19. Release and position aside the driver side C-pillar trim panel. 20. Disconnect the driver side safety canopy module electrical connector. 21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels. 23. Disconnect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10051 24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 25. Disconnect the driver side safety canopy module electrical connector. 26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 27. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10052 28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 29. Install the RCM fuse 17 (10A) to the SJB. 30. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10053 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10054 11. Connect the driver side safety canopy module electrical connector. 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10055 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10056 19. Connect the LH side passenger air bag module electrical connector. 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10057 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the 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 at a 5 Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification system module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb INSTRUMENT CLUSTER BULB Removal and Installation 1. Remove the instrument cluster (IC). 2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift out from the IC. Remove the illumination bulb(s). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 10062 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb WARNING INDICATOR BULB Removal and Installation 1. Remove the instrument cluster (IC). 2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise and lift it out from the instrument cluster (IC). Remove the warning indicator bulb(s) in question. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10071 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10077 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10083 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10084 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10085 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10086 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10092 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10093 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10094 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 10095 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Tire Pressure Monitoring System (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. Tire Pressure Monitoring System (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. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate. 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 Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. Tire Pressure Monitoring System (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 not received any 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 MESSAGE CENTER CONFIGURATION Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. - All message center functions are carried out using the single stem reset button in the instrument cluster. 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen Odometer: Customer Interest Instruments - Odometer Display Moves On Screen TSB 10-2-15 02/15/10 ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF MESSAGE CENTER SCREEN FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit a condition where the odometer display reading momentarily flips from the bottom to the top of the message center screen, then back to the normal display mode (Figure 1). This concern may be very intermittent and difficult to verify. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one required) which must be ordered directly from the supplier Newark listed below: ^ Newark telephone number 1-800-463-9275. ^ Newark website: www.Newark.com. ^ Newark part number: 78K6137. ^ Manufacturer: Fair Rite. ^ Manufacturer part number: 0444176451. 1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01. NOTE IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 10113 2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits. (Figure 3) 3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 10114 4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5) 5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the instrument cluster bracket. (Figure 6) 6. Install the IC. Refer to WSM, Section 413-01. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Odometer: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10119 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen Odometer: All Technical Service Bulletins Instruments - Odometer Display Moves On Screen TSB 10-2-15 02/15/10 ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF MESSAGE CENTER SCREEN FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit a condition where the odometer display reading momentarily flips from the bottom to the top of the message center screen, then back to the normal display mode (Figure 1). This concern may be very intermittent and difficult to verify. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one required) which must be ordered directly from the supplier Newark listed below: ^ Newark telephone number 1-800-463-9275. ^ Newark website: www.Newark.com. ^ Newark part number: 78K6137. ^ Manufacturer: Fair Rite. ^ Manufacturer part number: 0444176451. 1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01. NOTE IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 10125 2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits. (Figure 3) 3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 10126 4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5) 5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the instrument cluster bracket. (Figure 6) 6. Install the IC. Refer to WSM, Section 413-01. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Odometer: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10131 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10135 View 151-9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10136 C103 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation Outside Temperature Display: Description and Operation EXTERNAL TEMPERATURE DISPLAY The external temperature is displayed when the EXT button is pressed. While the actual external temperature can vary continuously, the value that is displayed will update at a specific rate depending on whether or not the engine is "hot" and whether or not the vehicle is moving. When the external temperature is rising, the display will update slowly. Updates (when the actual external temperature is higher than currently displayed value) will be limited to 0.6°C (1°F) every 20 seconds while the vehicle is moving at greater than 40 kph (25 mph) for more than 90 seconds OR 0.6°C (1°F) every 20 minutes if the vehicle is not moving at this speed. This is to prevent the heat from the engine compartment from affecting the accuracy of the display. When the external temperature is dropping, the display will update quickly. Updates (when the actual external temperature is lower than currently displayed value) will only be limited to 0.6°C (1°F) every 2 seconds (regardless of vehicle speed). Consequently the display will essentially follow the drop experienced by the external temperature thermistor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams Parking Assist Warning Indicator: Diagrams C3268 C4015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 10146 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 10147 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10157 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10163 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10172 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10178 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators or the Owner's Literature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators or the Owner's Literature. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Release the 2 tabs and remove the instrument panel dimmer switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 10189 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10194 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10195 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10196 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10197 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10200 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10201 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10202 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10203 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10206 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10207 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10208 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10209 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10210 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10211 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10212 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams C434A C434B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 10216 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 10217 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 10218 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 10219 Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the fuel pump body. 2. Route the fuel level sender wire through the center of the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 10220 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations View 151-18 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 10224 View 151-19 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 10225 C2015 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Tire Pressure Monitoring System (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. Tire Pressure Monitoring System (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. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate. 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 Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. Tire Pressure Monitoring System (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 not received any 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the smart junction box (SJB). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. 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 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 activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 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. NOTE: Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 10234 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the SJB and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform the SJB on-demand self test. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 10235 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode, it will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10238 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10239 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10240 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10241 WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. 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 inch) 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 may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10242 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 and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-inch). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10243 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10251 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10252 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10257 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10258 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Brake Lamp: Connector Views C4032 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 C4034 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10278 C4035 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10279 C4036 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10280 C418 C419 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10281 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10282 90-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is in the LOW BEAM position. 4. NOTE: Make sure to use the latest scan tool release software. 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 PCM. 7. Carry out the network test. - If the scan tool responds with no communication with the SJB, 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 DTC Charts. 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 Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The SJB monitors the input from the stoplamp switch. When the brake pedal is applied, voltage is routed to the SJB. The SJB then supplies voltage to the stoplamps. Field-Effect Transistor (FET) Protection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10285 The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a customer demand of the function (switching the component on, battery saver being energized). When an excessive circuit load occurs several times, the module shuts down the output until a repair procedure is carried out. At the same time, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal until a successful on-demand self-test proves that the fault has been repaired. After the on-demand self-test has successfully completed (no on-demand DTCs present), the continuous DTC clears and the circuit function returns. Each circuit has 3 predefined levels of short circuit tolerance established in the module based on each circuits' capability. When the first or second level is reached, the continuous DTC associated with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are shorted past the third level, then B106F and B1342 set along with the associated continuous DTC. These DTCs cannot be cleared and the module must be replaced. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10286 Brake Lamp: Diagnostic Trouble Code Descriptions B2048-B2049 B2050-B2051 / C1446-C1788 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10287 Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10288 Brake Lamp: Pinpoint Tests Test H: All The Stoplamps Are Inoperative PINPOINT TEST H: ALL THE STOPLAMPS ARE INOPERATIVE Normal Operation The stoplamp switch is supplied voltage through circuit SBP22 (BN/RD) from the smart junction box (SJB). When the brake pedal is applied, the stoplamp switch routes voltage to the SJB through circuit CCB08 (VT/WH) which then supplies voltage to all the stoplamps. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Stoplamp switch - SJB H1-H2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10289 H3-H5 Test I: One Or More Stoplamps Are Inoperative PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE Normal Operation - All Vehicles When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB). The voltage is then routed out of the SJB to the high mounted stoplamp through circuit CCB08 (VT/WH). Explorer When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high mounted stoplamp and the LH rear stoplamp is provided through circuit GD149 (BK/GY). Ground for the RH rear stoplamp is provided through circuit GD151 (BK/GN). Explorer Sport Trac When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high mounted stoplamp is provided through circuit GD133 (BK). Ground for the LH and RH rear stoplamps is provided through circuit GD148 (BK/YE). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10290 Mountaineer When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuit CLS44 (VT/BN). Ground for the high mounted stoplamp and the LH rear stoplamp is provided through circuit GD149 (BK/GY). Ground for the RH rear stoplamp is provided through circuit GD151 (BK/GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - High mounted stoplamp - LED module - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10291 I1-I6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10292 I6-I8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10293 I8-I10 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10294 I10-I12 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10295 I12-I13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10296 I14-I15 Test J: The Stoplamps Are On Continuously PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY Normal Operation - All Vehicles When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB), the brake shift interlock actuator, the trailer brake control (TBC) module, the 4X4 control module, the ABS module, and the PCM through circuit CCB08 (VT/WH). The voltage is then routed out of the SJB to the high mounted stoplamp through circuit CCB08 (VT/WH). Explorer, Explorer Sport Trac When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Mountaineer When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuit CLS44 (VT/BN). - DTC B1446 (Brake Switch Circuit Failure) - is an on-demand DTC that sets when the SJB detects a short to voltage from the brake pedal applied input circuit. - DTC B2049 (Left Rear Turn Lamp Circuit Open) - is a continuous and on-demand DTC that sets when the SJB detects a short to voltage from the LH rear turn lamp voltage supply circuit. - DTC B2051 (Right Rear Turn Lamp Circuit Open) - is a continuous and on-demand DTC that sets when the SJB detects an open from the RH rear turn lamp voltage supply circuit. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Stoplamp switch - Trailer brake control (TBC) module - Brake shift interlock actuator - 4X4 control module - ABS module - PCM - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10297 J1-J8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10298 J9-J13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10299 J14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10300 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10304 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10305 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10306 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10307 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp C926 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp > Page 10312 C927 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams C475 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams C254 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10324 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10325 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10326 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10327 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10328 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10329 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10330 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10331 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10332 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10333 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10334 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10335 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10336 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10337 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10338 97-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Daytime Running Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is not in the HIGH BEAM position. 3. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 4. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 5. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 6. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 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 NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The DRL feature operates the low beam headlamps at a reduced intensity when the ignition switch is in the RUN position, the headlamps are not on from any other input, and the transmission is not in PARK (P). 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10341 Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10342 Daytime Running Lamp: Pinpoint Tests PINPOINT TEST AE: THE DAYTIME RUNNING LAMPS (DRL) ARE INOPERATIVE Normal Operation When the ignition switch is in the RUN position, the headlamps are not on (from the autolamp system or manual control from the headlamp switch) and the transmission is not in PARK (P), the smart junction box (SJB) provides a pulse-width modulated (PWM) voltage to the low beam headlamps. This illuminates the headlamps at a reduced intensity. This pinpoint test is intended to diagnose the following: - Exterior lighting system input/output - Ignition switch input - Transmission gear input - SJB AE1-AE4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 10343 Daytime Running Lamp: Adjustments AUTOLAMPS TIME DELAY ADJUSTMENT NOTE: Steps 2 through 5 must be carried out within a 10-second period. 1. Start with the ignition switch OFF position and the headlamp switch in the AUTOLAMPS ON position. 2. Place the headlamp switch in the OFF position. 3. Place the ignition switch in the RUN position. 4. Place the ignition switch in the OFF position. 5. Place the headlamp switch in the AUTOLAMPS ON position. The exterior lamps turn on at this point. 6. Wait the desired amount of time and place the headlamp switch in the OFF position (maximum of 3 minutes). The exterior lamps turn off and the autolamp time delay is now set. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 10344 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Release the 2 tabs and remove the instrument panel dimmer switch. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page 10348 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front Dome Lamp: Service and Repair Interior Lamp - Front INTERIOR LAMP - FRONT Removal and Installation 1. NOTE: Use a small screwdriver to pry open the garage door opener bin. Open the rear overhead console storage or garage door opener bin to access the retaining screw. Remove the screw. 2. Pull the front of the overhead console down and remove the console from the console retaining clips. - Disconnect the electrical connector(s). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front > Page 10353 Dome Lamp: Service and Repair Interior Lamp - Rear INTERIOR LAMP - REAR Removal and Installation 1. Remove the rear interior lamp lens. 2. Release the 2 retaining clips (through the access holes) and remove the rear interior lamp assembly. - Disconnect the electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front > Page 10354 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10359 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10360 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10361 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10362 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10365 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10366 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10367 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10368 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10371 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10372 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10373 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10374 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10375 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10376 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10377 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Base Fog Lamp Bulb Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Page 10382 Adrenalin Package Fog Lamp Bulb Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: - The fog lamp bulb should not be removed from the fog lamp assembly until just before a new bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp assembly where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed from the fog lamp assembly. - Make sure the headlamp switch and ignition switch are in the OFF position. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with base fog lamp 2. NOTE: To remove, rotate the bulb approximately one-eighth turn counter clockwise. Disconnect the electrical connector and remove the fog lamp bulb. Vehicles with Adrenalin fog lamp 3. NOTE: To remove, squeeze the tabs and pull the fog lamp bulb from the fog lamp assembly. Disconnect the electrical connector and remove the fog lamp bulb. All vehicles 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10386 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Explorer, Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 10395 Mountaineer Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: The headlamp bulb should not be removed from the headlamp assembly 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 assembly where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp assembly. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb one-eighth turn counterclockwise and remove the headlamp bulb. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10400 Headlamp Dimmer Switch: Locations Multifunction Switch View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10401 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 10404 C2298 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10407 Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10408 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10409 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10410 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10414 C205 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10415 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10416 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10417 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10426 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10427 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10428 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10429 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10430 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10431 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10432 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10433 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10434 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10435 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10436 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10437 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10438 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10439 License Plate Lamp: Connector Views C452 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10440 C454 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10441 C462 C464 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10442 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10443 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10448 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10449 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10450 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10451 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10452 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10453 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10454 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10455 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10456 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10457 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10458 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10459 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10460 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10461 Marker Lamp: Connector Views C1127 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10462 C1126 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10463 C481 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10464 C482 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10465 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10466 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 10467 Marker Lamp: Service and Repair SIDE MARKER LAMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the socket from the side marker lamp. 3. Remove the 2 nuts and the side marker lamp. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair PARKING LAMP BULB - FRONT Explorer, Explorer Sport Trac Mountaineer Removal and Installation 1. Remove the headlamp assembly. 2. Remove the parking lamp bulb socket from the headlamp assembly. - Remove the parking lamp bulb from the socket. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 10475 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10480 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10487 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10492 C286 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10493 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10497 View 151-11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10498 C167 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10502 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10503 C278 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10504 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10505 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10510 Door Switch: Locations Door Ajar Switch View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10511 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10512 View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10513 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch C478 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10516 Door Switch: Diagrams Door Ajar Switch C526 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10517 C602 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10518 C715 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10519 C820 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10522 Part 2 Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10523 Door Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10524 Part 2 Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10525 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10526 Part 2 Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10527 Door Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10528 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10533 Headlamp Dimmer Switch: Locations Multifunction Switch View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10534 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 10537 C2298 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10540 Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10541 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10542 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10543 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-13 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10547 C205 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10548 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10549 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10550 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-16 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10557 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10558 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10559 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10560 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10561 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10567 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10568 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10569 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10570 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10571 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10572 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10573 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10574 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10575 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10576 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10577 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10578 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10579 Tail Lamp: Connector Views C418 C419 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10580 C4032 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10581 C4034 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10582 C4035 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 C4036 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10605 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Principles of Operation PRINCIPLES OF OPERATION NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer turn lamps. The trailer parking and reversing lamps share the vehicle lighting outputs. The vehicle is supplied with wiring to support an aftermarket trailer brake control (TBC) module. The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer tow connector. Field-Effect Transistor (FET) Protection The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a customer demand of the function (switching the component on, battery saver being energized). When an excessive circuit load occurs several times, the module shuts down the output until a repair procedure is carried out. At the same time, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal until a successful on-demand self-test proves that the fault has been repaired. After the on-demand self-test has successfully completed (no on-demand DTCs present), the continuous DTC clears and the circuit function returns. Each circuit has 3 predefined levels of short circuit tolerance established in the module based on each circuits' capability. When the first or second level is reached, the continuous DTC associated with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are shorted past the third level, then B106F and B1342 set along with the associated continuous DTC. These DTCs cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer stop/turn output circuits. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched) - 17 (30A) (trailer brake control (TBC) module) - Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps) - 12 (5A) (trailer tow battery charge relay coil) - 16 (10A) (trailer reversing lamps) - 25 (15A) (trailer parking lamps) - Circuity - Trailer - SJB 4. 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. 5. NOTE: Make sure to use the latest scan tool release software. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10608 6. 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. 7. 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 PCM. 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 10. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10609 B2070 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10610 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10611 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10612 Trailer Lamps: Pinpoint Tests Test W: All The Trailer Lamps Are Inoperative PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE Normal Operation Ground for the all trailer lamps is provided through circuit RAT08 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer W1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10613 W1-W2 Test X: The Trailer Lamps Are Inoperative - Parking Lamps PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING Normal Operation When the vehicle parking lamps are on, the smart junction box (SJB) provides voltage to the trailer parking lamps through circuit CAT17 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10614 X1-X2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10615 X2-X4 Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS Normal Operation Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10616 Y1-Y3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10617 Y3-Y4 Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP Normal Operation Voltage to the LH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit CAT06 (YE). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the SJB detects a short to ground from the LH trailer stop/turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the LH trailer stop/turn lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10618 Z1-Z6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10619 Z6-Z7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10620 Z8-Z9 Tests AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN LAMP Normal Operation Voltage to the RH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit CAT09 (GN). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the SJB detects a short to ground from the RH trailer stop/turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the RH trailer stop/turn lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10621 AA1-AA6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10622 AA6-AA7 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10623 AA8-AA9 Tests AB: The Trailer Lamps Are On Continuously PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE) and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively. The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer - SJB AB1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10624 AB1-AB3 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 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A) through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay switch 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer battery charge relay - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10625 AC1-AC3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10626 AC3-AC4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10627 AC5-AC6 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10628 AC6 Continued Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10629 AC7-AC9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10630 AC9-AC11 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10631 AC11-AC12 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 Normal Operation The trailer brake control (TBC) module is provided voltage at all times by the battery junction box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides voltage to the trailer tow connector through circuit CAT19 (BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer tow connector - Trailer Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10632 AD1-AD3 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10633 AD3-AD5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10634 AD6-AD8 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10635 AD8-AD9 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 10636 Special Tool(s) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10640 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp Turn Signal Lamp: Diagrams Turn Lamp C413 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10649 C416 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10650 Turn Signal Lamp: Diagrams Park/Turn Lamp C1023 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10651 C1115 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10652 C1043 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10653 C1116 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10654 Turn Signal Lamp: Diagrams Park/Stop/Turn Lamp C4032 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10655 C4034 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10656 C4035 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10657 C4036 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10658 Turn Signal Lamp: Diagrams Repeater Lamp C1108 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp > Page 10659 C1109 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10663 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10664 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10665 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10666 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10667 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left C907 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 10672 C906 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10679 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10680 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10683 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10684 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10685 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10686 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10687 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 10691 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10697 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10698 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10701 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10702 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10703 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10704 Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10705 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 10710 C2347 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10715 Power Window Switch: Locations Window Adjust Switch View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10716 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10717 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10718 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch C980 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10721 Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10722 C504B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10723 Power Window Switch: Diagrams Window Adjust Switch C604 C701 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10724 C801 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10727 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10728 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10729 Power Window Switch: Testing and Inspection Rear Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 10730 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Testing and Inspection Back Window Motor: Testing and Inspection WINDOW MOTOR INITIALIZATION - REAR WARNING: Keep objects and body parts clear of the glass panel when carrying out the initialization procedure. During the initialization procedure, the glass panel closes with high force and cannot detect objects in its path. Failure to follow this instruction may result in serious personal injury. NOTE: - The rear window motor is in error mode when shipped and will be inoperative until initialized. - This procedure must be carried out when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. - All power rear window components (window glass module, window regulator, window motor and glass runs) must be installed and tightened to specification before carrying out this procedure. 1. Open the driver door. 2. Turn the ignition to the ON position. 3. Cycle the ignition OFF and then back to ON position 5 times. 4. With the ignition still in the ON position, depress and hold the power rear window control switch in the down position until the rear widow stalls in the fully open position. Release the control switch. 5. Depress and hold the power rear window control switch in the up position until the rear window stalls in the fully closed position. Release the control switch. 6. Verify correct operation of the power rear window by moving the window to the VENT, fully OPEN and fully CLOSED positions. If the window does not operate correctly, carefully repeat this procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Testing and Inspection > Page 10736 Back Window Motor: Service and Repair WINDOW REGULATOR MOTOR - REAR Exploded View Removal and Installation NOTE: The rear window regulator motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. 1. Remove the rear window glass regulator. 2. Remove the 3 window regulator motor bolts. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the window regulator motor. 4. To install, reverse the removal procedure. - Initialize the rear window regulator motor. For additional information, refer to Window Motor Initialization - Rear. See: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 10740 Part 2 Removal and Installation 1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Page 10744 Part 2 Removal and Installation 1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3. Remove the 3 window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the window regulator motor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch View 151-37 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10749 Power Window Switch: Locations Window Adjust Switch View 151-34 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10750 View 151-33 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10751 View 151-32 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Rear Window Adjust Switch > Page 10752 View 151-31 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch C980 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10755 Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10756 C504B Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10757 Power Window Switch: Diagrams Window Adjust Switch C604 C701 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10758 C801 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10761 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10762 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10763 Power Window Switch: Testing and Inspection Rear Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 10764 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed Back Window Glass: Service and Repair Window Glass - Rear, Fixed WINDOW GLASS - REAR, FIXED Material Material Removal NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass. 1. Remove the cab rear panel. 2. Remove the 15 rear window glass mounting nuts. 3. CAUTION: Use only a plastic windshield setting tool to slide under the seal to separate the foam core butyl from the glass. Once the glass starts to separate from the body, constant hand pressure will break the seal and the glass can be removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame. Remove the rear window glass. Installation 1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window glass prior to installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10770 Install the rear window glass. Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the bottom middle of the rear window glass. - Carefully install the rear window glass into the body opening. 2. Install the 15 rear window glass mounting nuts. - Tighten to 3 Nm (27 lb-in). - Test the rear window glass for water leaks. 3. Install the cab rear panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10771 Back Window Glass: Service and Repair Window Glass - Rear, Power WINDOW GLASS - REAR, POWER Material Material Removal NOTE: - The rear window regulator motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. - If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass. 1. Remove the rear window glass regulator. 2. Remove both C-pillar upper trim panels. 3. Remove the 12 rear window glass mounting nuts. 4. CAUTION: Use only a plastic windshield setting tool to slide under the seal to separate the foam core butyl from the glass. Once the glass starts to separate from the body, constant hand pressure will break the seal and the glass can be removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10772 Remove the rear window glass. Installation 1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window glass prior to installation. Install the rear window glass. Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the bottom middle of the rear window glass. - Carefully install the rear window glass into the body opening. 2. Install the 12 rear window glass mounting nuts. - Tighten to 3 Nm (27 lb-in). - Test the rear window glass for water leaks. 3. Install both C-pillar upper trim panels. 4. Install the rear window glass regulator. - Initialize the rear window regulator motor. For additional information, refer to Window Motor Initialization - Rear. See: Power Window Motor/Back Window Motor/Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10777 Part 2 Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Special Tool(s) Special Tool(s) Material Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 10781 Removal 1. Remove the rear quarter trim panel. 2. Remove the wiring harness brackets. 3. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area. - Use a clean shop towel or oil-free compressed air. 4. NOTE: Refer to manufacturer's instructions before using the special tool. Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive. 5. NOTE: Locating tabs need to be cut through in order to remove the rear quarter window glass. The new rear quarter window glass will be equipped with new locating tabs. Lubricate the urethane adhesive with water to aid the special tool when cutting. 6. WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Insert the blade into the special tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement glass. - Support the glass to prevent the glass from dropping while cutting the urethane adhesive. Insert the special tool at the upper center of the quarter window glass and work toward the bottom corners. 7. Insert the Interior Auto Glass Cut-Out Knife Kit into the bottom of the remaining urethane adhesive and cut from corner to corner. Carefully remove the quarter glass from the vehicle and place on a stable work surface. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 10782 Installation 1. Dry fit the rear quarter window glass in the window opening. - Position the quarter window glass on the pinch weld. - Center the quarter glass in the opening for best fit. - Make alignment marks with tape or non-staining grease pencil on the quarter window glass and the body. 2. After the dry-fit alignment, remove the glass from the opening and place on a stable work surface with the interior side of the glass facing upward. 3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations. Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinch weld. 4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane. Remove any foreign material or water that may have entered during glass removal. 5. If reinstalling the same quarter window glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead. 6. Clean the inside of the new quarter window glass with glass cleaner. - Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied. 7. NOTE: - 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. - Sika uses the same black primer for the glass and pinch weld area. If installing a new rear quarter window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 8. Cut the urethane adhesive applicator tip to specification. 9. NOTE: - Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead. - The quarter glass must be positioned within 10 minutes of applying the urethane adhesive. Use caution when applying urethane adhesive. Apply to the outside edges of the locating tabs on the glass surface. Start at the bottom and work around to the sides of the rear quarter window glass. Make sure that all gaps in the urethane bead are smoothed into one continuous bead. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 10783 10. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). CAUTION: Before positioning the quarter window glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond. Using the alignment marks made previously, position the quarter window glass on the pinch weld. 11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 12. Install the wiring harness brackets. 13. Install the rear quarter trim panel. 14. Clean the exterior and interior of the quarter window glass with glass cleaner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10788 Part 2 Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair WINDOW REGULATOR - REAR Exploded View Removal and Installation NOTE: The rear window regulator motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. 1. Remove the cab rear panel. 2. Position the insulator aside. 3. Remove the 8 window regulator cover bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 10793 - To install, tighten to 10 Nm (89 lb-in). 4. Remove the window regulator cover-to-motor bolt. - To install, tighten to 10 Nm (89 lb-in). 5. Remove the window regulator cover. 6. Remove the 2 window regulator mounting nuts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the 2 window regulator-to-window bolts. - To install, tighten to 11 Nm (8 lb-ft). 8. Disconnect the electrical connector. 9. Remove the window regulator. 10. To install, reverse the removal procedure. - Initialize the rear window regulator motor. For additional information, refer to Window Motor Initialization - Rear. See: Power Window Motor/Back Window Motor/Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10797 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector. 5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield. 7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement. 9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. Damage to the window regulator will occur if the holes become enlarged. The new rivets may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window glass-to-regulator rivets. 10. Secure the front door glass in the full UP position with tape. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10798 11. Disconnect the window regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the window regulator assembly. 14. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 10802 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior moulding. 4. Remove the rear door weather shield. 5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. Damage to the window regulator will occur if the hole becomes enlarged. The new rivet may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window glass-to-regulator rivet. 6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window regulator motor electrical connector. 8. Remove the 2 rear window regulator mounting nuts. - To install, tighten to 10 Nm (89 lb-in). 9. Remove the 3 window regulator motor bracket nuts. - To install, tighten to 10 Nm (89 lb-in). 10. Remove the window regulator assembly. 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures Windshield: Procedures GLASS RESEAL - WINDSHIELD Material Material 1. Remove the RH and LH side A-pillar trim panel. 2. Remove the sun visors, retainers and, if equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove the interior mirror. 5. Lower the front portion of the headliner. 6. Remove the cowl panel grille. 7. Clean the edge formed by the existing urethane and the glass on the inside at the top, sides and outside on the bottom of the windshield with glass cleaner. 8. Cut the urethane applicator tip to specification. 9. NOTE: - Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. - Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. Apply a bead of urethane adhesive over the top of the existing urethane adhesive. Apply the urethane adhesive to the top and sides of the windshield glass from the interior of the vehicle. - Apply the urethane adhesive to the bottom of the windshield glass from the exterior of the vehicle. 10. NOTE: 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. 11. Install the cowl panel grille. 12. Raise the front portion of the headliner. 13. Install the interior mirror. 14. Install the sun visors, retainers and, if equipped, the overhead console. 15. If equipped, install the roof opening panel trim. 16. Install the RH and LH side A-pillar trim panels. 17. Clean the exterior and interior of the windshield glass with glass cleaner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10807 Windshield: Removal and Replacement WINDSHIELD GLASS Special Tool(s) Special Tool(s) Material Material Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10808 Removal 1. Remove the RH and LH side A-pillar trim panels. 2. Remove the sun visors and retainers and, if equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove the interior mirror. 5. Lower the front portion of the headliner. 6. Remove the cowl panel grille. 7. NOTE: LH shown, RH similar. If equipped, disconnect the heated windshield electrical connectors. Disconnect the connector. - Remove the connector from the retainer. - Remove the connector from the stud. 8. NOTE: LH shown, RH similar. Lower the setting blocks. Use a flat screwdriver to release the setting block and lower. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10809 9. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area. - Use a clean shop towel or oil-free compressed air. 10. NOTE: Refer to manufacturer's instructions before using the special tool. Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive. 11. WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Insert the blade into the special tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass. - Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive. Insert the special tool at the upper center of the windshield glass and work toward the bottom corners. 12. Using the special tool, distance the windshield from the body. 13. Insert the Interior Auto Glass Cut-Out Knife Kit into the bottom of the remaining urethane adhesive and cut from corner to corner. 14. NOTE: - Removing the windshield glass requires more than one technician. - If reinstalling the windshield glass, tape the windshield at the windshield stops to aid in alignment of the glass during installation. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10810 Carefully remove the windshield glass from the vehicle and place on a stable work surface. Installation 1. NOTE: Raise the setting block until flush with top. Lock the blocks into place after windshield is installed. Raise the setting blocks. 2. Dry-fit the new windshield glass on the existing urethane bead on the pinch weld. - Position the windshield glass on the pinch weld. - Center the windshield glass in the opening. - Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass setting blocks) on the windshield glass and the body. 3. After the dry-fit alignment, remove the glass assembly from the windshield opening and place on a stable work surface with the interior side of the glass facing upward. 4. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations. Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinch weld. 5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane. Remove any foreign material or water that may have entered during windshield removal. 6. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead. 7. NOTE: Inspect the flat foil connectors at the bottom of the new windshield for damage prior to installation. Do not install a windshield with damaged flat foil connectors. Clean the inside of the new windshield glass with glass cleaner. Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied. 8. NOTE: - 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. - Sika uses the same black primer for the glass and pinch weld area. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10811 If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 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 continuous bead. - The windshield glass must be positioned within 10 minutes of applying the urethane adhesive. Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane bead on the pinch weld. Make sure that all gaps in the urethane bead are smoothed into one continuous bead. 11. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). CAUTION: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond. Using the alignment marks made previously, position the windshield glass on the pinch weld. 12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 13. NOTE: Follow the same routing for the electrical connector that was used during removal. If equipped, connect the heated windshield electrical connectors. 14. Install the cowl panel grille. 15. Raise the front portion of the headliner. 16. Install the interior mirror. 17. Install the sun visors, retainers and, if equipped, the overhead console. 18. If equipped, install the roof opening panel trim. 19. Install the RH and LH side A-pillar trim panels. 20. Clean the exterior and interior of the windshield glass with glass cleaner. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10817 C4323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 10821 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10826 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10827 C138 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10831 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10832 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10835 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 10836 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10837 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10838 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10842 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10843 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10846 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10847 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10848 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10849 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10853 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10854 C138 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor Windshield Washer Motor: Locations Two-Way Washer Pump Motor View 151-1 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 10859 View 151-4 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 10860 Windshield Washer Motor: Locations Washer Pump Motor View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 10861 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Washer Pump Motor C137 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Washer Pump Motor > Page 10864 C1397 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair WASHER PUMP Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 10868 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 10869 Washer Pump And Reservoir Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the windshield washer pump electrical connector. 3. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Failure to follow these instructions may result in serious personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Disconnect the windshield washer reservoir hoses. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 10870 4. NOTE: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. Remove the windshield washer pump. 5. CAUTION: Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER RESERVOIR Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10874 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10875 Washer Pump And Reservoir Removal and Installation 1. Remove the air cleaner assembly. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the RH front fender splash shield. 4. Disconnect the windshield washer pump electrical connector. 5. Disconnect the windshield washer solvent level electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10876 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Failure to follow these instructions may result in serious personal injury. NOTE: If necessary, drain the windshield washer reservoir after removal. 6. Disconnect the windshield washer reservoir hoses. 7. Remove the top bolt. - To install, tighten to 5 Nm (44 lb-in). 8. Remove the side bolt. - To install, tighten to 5 Nm (44 lb-in). 9. Remove the bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10877 - To install, tighten to 5 Nm (44 lb-in). 10. Remove the windshield washer pump reservoir. 11. CAUTION: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. Transfer components as necessary. 12. CAUTION: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10881 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10882 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10885 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10886 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10887 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10888 Steering Column Multifunction Switch (Part 2) Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. ^ To install, tighten to 3 Nm (27 lb-inch). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments WIPER BLADE AND PIVOT ARM ADJUSTMENT - WINDSHIELD 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (1) RH windshield wiper blade and the (3) bottom of the windshield glass to be sure the distance is within specification. 3. Verify the distance between the center of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass to be sure the distance is within specification. 4. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from returning to the fully parked position. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10894 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10895 Washer Pump And Reservoir Removal and Installation 1. Remove the wiper pivot arm. 1 Pull up on the pivot arm. 2 Pull out on the retaining tab and remove the pivot arm. 2. NOTE: The windshield wiper motor must be cycled to make sure that it is in the park position. If necessary, adjust the wiper pivot arms. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10896 Wiper Arm: Service and Repair Wiper Pivot Arm - Rear WIPER PIVOT ARM - REAR Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10897 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10898 Washer Pump And Reservoir Removal 1. Remove the wiper pivot arm cover. 2. Remove the wiper pivot arm. 1 Remove the pivot arm nut. 2 Remove the wiper pivot arm. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10899 Installation 1. NOTE: Before installation, be sure that the rear window wiper motor is in the park position. Turn the wiper switch ON and OFF to allow the rear window wiper motor to cycle and stop in the park position. 2. Position the wiper pivot arm. 3. Install the pivot arm nut. - Tighten to 17 Nm (13 lb-ft). 4. Install the wiper pivot arm cover. 5. Operate the rear window wiper for one cycle to be sure that the pivot arm is in the correct position when the rear window wiper motor is in the park position. If the pivot arm is not in the correct position, remove the pivot arm and repeat Steps 1 through 4. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-35 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10903 C4323 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations View 151-2 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10907 View 151-5 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10910 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition for all removable relays, pin positions are added to illustrate proper orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10911 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 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 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10912 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10913 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10914 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10915 Symbols (Part 4) Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10916 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 terminal by pulling each wire at the end of the connector. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10917 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10918 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10919 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. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10920 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10921 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10922 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10923 C125 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) 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 Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10926 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10927 Washer Pump And Reservoir Removal and Installation NOTE: A new wiper motor assembly comes with the linkage arm installed. 1. Remove the front wiper pivot arms. 2. Remove the RH cowl grille panel. 3. Remove the LH cowl grille panel. 4. Disconnect the windshield wiper motor electrical connector. - Unclip the wiring harness from the wiper arm. - Position the wiring harness aside. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10928 5. Remove the 3 windshield wiper assembly mounting bolts. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the windshield wiper assembly and position on a workbench. 7. CAUTION: Do not remove the wiper motor linkage arm from the wiper motor assembly. If the arm is removed, the wiper arms may not park in the correct location. Separate the wiper motor linkage arm from the wiper mounting arm and pivot shaft assembly. - Use a suitable tool at the location shown to separate the wiper linkage arm from the wiper mounting arm and pivot shaft assembly. 8. Remove the 3 windshield wiper motor mounting bolts. - To install, tighten to 15 Nm (11 lb-ft). 9. Remove the windshield wiper motor. 10. NOTE: The windshield wiper motor must be cycled to make sure it is in the park position before installing the wiper pivot arms. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10929 Wiper Motor: Service and Repair Wiper Motor - Rear Window WIPER MOTOR - REAR WINDOW Exploded View Windshield Wipers Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10930 Rear Wiper Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10931 Washer Pump And Reservoir Removal and Installation 1. Remove the rear wiper pivot arm. 2. Remove the rear window wiper motor grommet. 1 Remove the pivot shaft nut. To install, tighten to 10 Nm (89 lb-in). 2 Remove the grommet. 3. Open the liftgate window. 4. Remove the wiper motor cover trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10932 5. Remove the rear window wiper motor. 1 Disconnect the electrical connectors. 2 Remove the 2 rear window wiper motor nuts. To install, tighten to 6 Nm (53 lb-in). 3 Remove the rear window wiper motor. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 10936 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations View 151-14 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10940 View 151-15 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10941 C202 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10944 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10945 Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10946 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Steering Column Multifunction Switch (Part 1)